Heat exchanger components having varying helix angles

Abstract

The heat exchanger component can have a ceramic body having a central cavity extending along the length of the body, a plurality of helices extending around the central cavity, a plurality of inter-helical channels disposed between the plurality of helices, and a plurality of intra-helical channels contained within the plurality of helices, wherein the twist angle of each helix of the plurality of helices varies with respect to the length of the body. The heat exchanger component can be used to provide a three-flow path heat exchanger, and can achieve exceptional efficiency while being economical to manufacture.

Description

[Technical field]

[0001] SUMMARY The present disclosure relates to a heat exchanger component having a ceramic body, and to a heat exchanger including the heat exchanger component. [Background technology]

[0002] Standard industrial high temperature heat exchangers operating at temperatures above 800°C typically support efficiencies approaching 70%. Regenerative heat exchangers can achieve improved efficiencies up to 88%. However, regenerative heat exchangers require a complex set of two burners, regenerative beds, and computer controlled valves that make the cost of regenerative systems very high. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] U.S. Patent No. 8,162,040 Summary of the Invention

[0004] There is a need to develop heat exchangers that bridge the gap between standard industrial systems and regenerative systems, improving efficiency and cost.

[0005] The present disclosure may be more fully understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings. [Brief description of the drawings]

[0006] [Figure 1] FIG. 2 illustrates a section of a body of a heat exchanger component according to one embodiment. [Diagram 2] 1 is a cross-sectional side view of a heat exchanger including a heat exchanger component according to one embodiment. [Diagram 3] FIG. 13 is a cross-sectional side view of a helix attached to a surface of a tube wall according to one embodiment. [Figure 4] FIG. 2 is a cross-sectional side view of two helices attached to the surface of a tube wall according to one embodiment. [Diagram 5] FIG. 2 is a perspective view of a body of a heat exchanger component according to one embodiment. [Figure 6] 1 is a perspective view of a longitudinal cross section of a body of a heat exchanger component according to one embodiment; FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having," or any other variations thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus having a list of features is not necessarily limited to only those features and may include other features not expressly listed or that are inherent to such process, method, article, or apparatus.

[0008] As used herein, unless expressly stated to the contrary, "or" means an inclusive or rather than an exclusive or. For example, a condition A or B is satisfied by any of the following: A is true (or present) and B is false (or absent), A is false (or absent) and B is true (or present), and both A and B are true (or present).

[0009] Additionally, the use of "a" or "an" is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one, and the singular also includes the plural unless it is clear that this is meant otherwise.

[0010] The present disclosure is directed to a heat exchanger component having a body comprising a ceramic. The body includes a plurality of helices extending around a central cavity of the body, with each helix varying in twist angle with respect to the length of the body. The heat exchanger component of the present disclosure can be adapted as an insert for use in a radiant U or W tube, such as those typically used in steel annealing, coating, or heat treating furnaces. A particular use of the heat exchanger insert of the present disclosure can be for large diameter heat exchangers for waste energy recovery. As used herein, the term "heat exchanger component" is used interchangeably with the term "heat exchanger insert."

[0011] A non-limiting example of a body of a heat exchanger component is shown in Figure 1. The body can include a plurality of helices (11) that can extend around a tube (12) that surrounds a central cavity (not visible). It can be seen that a first helix angle α1 at a proximal end (18) of the body is different from a second helix angle α2 at a distal end (19) of the body.

[0012] In one embodiment, the plurality of helices (11) can contain a plurality of intraspiral channels (not shown in FIG. 1). In certain embodiments, each helix of the plurality of helices can include at least one intraspiral channel. The helices can be disposed next to each other with a space between them, referred to herein as an interspiral channel (14). As used herein, the term intraspiral channel refers to a hollow channel within a helix, while the term interspiral channel refers to a channel formed by the space between two helices.

[0013] In another embodiment, as illustrated in FIG. 2, the heat exchanger components can be inserted into a pipe that fits precisely around the helix, thereby forming a heat exchanger. The heat exchanger can have three fluid flow paths to allow different fluids to flow from the proximal end to the distal end of the heat exchanger or vice versa. The first flow path is the path of hot gas (16) coming from the location of heat generation, also referred to herein as heat generating gas, e.g., hot gas developed by the combustion flame of a burner. The heat generating gas (16) can enter the heat exchanger at the proximal end (18), flow through the inter-helical channels (14) between the multiple helices (11), and exit the heat exchanger at the distal end (19). A second flow path may enter at the distal end (19) of the heat exchanger and pass cool air (15A) through the intrahelical channels (17) of the helices (11) in a counter-flow direction to the flow of the heat-generating gas (16). While flowing through the intrahelical channels (17), the air (15A) is heated by exchange of heat with the heat-generating gas (16), where the heat is transferred through the walls of the helices so that the two gases cannot mix. A portion of the heated air arriving at the proximal end (18) of the heat exchanger may be used to mix with the fuel gas to supply the burner (not shown), while another portion of the heated air may be returned and directed through the central cavity (13) surrounded by the central tube (12) as a third flow path. In one embodiment, all of the heated air (15B) can be returned to the proximal end (18) of the heat exchanger and can flow back through the central cavity (13) of the tubes (12) to the distal end (19) and out of the heat exchanger for further use.

[0014] It should be noted that the fluid that can flow through the heat exchanger of the present disclosure is not limited to gas, but can be liquid, or both gas and liquid, as described in the above embodiments.

[0015] In a particular embodiment, as shown in Figure 1, the first twist angle α1 at the proximal end (18) of the body can be greater than the second twist angle α2 at the distal end (19) of the body. In another particular embodiment (not shown), the first twist angle α1 at the proximal end of the body can be less than the second twist angle α2 at the distal end of the body.

[0016] In one embodiment, the twist angle can vary by at least 1 degree per 0.1 meter of the body, e.g., at least 3 degrees per 0.1 meter of the body, or at least 5 degrees per 0.1 meter of the body, or at least 7 degrees per 0.1 meter of the body, or at least 10 degrees per 0.1 meter of the body, or at least 15 degrees per 0.1 meter of the body, or at least 20 degrees per 0.1 meter of the body. As used herein, the term "along the body" is intended to mean from the proximal end (18) to the distal end (19) of the body, or vice versa.

[0017] In one particular embodiment, the helix angle can increase or decrease continuously along the length of the body, while in another particular embodiment, the helix angle can increase or decrease discontinuously along the length of the body.

[0018] In one embodiment, the twist angle of the helix over the length of the body can be at least 15 degrees, or at least 20 degrees, or at least 25 degrees, or at least 30 degrees, or at least 35 degrees, or at least 40 degrees, or at least 45 degrees, or at least 50 degrees, or at least 60 degrees. In another embodiment, the twist angle can be 90 degrees or less, e.g., 85 degrees or less, 80 degrees or less, 75 degrees or less, 70 degrees or less, 65 degrees or less, or 60 degrees or less. Further, the twist angle can be within a range including any of the minimum and maximum values ​​listed above, e.g., at least 15 degrees and not more than 90 degrees, or at least 20 degrees and not more than 80 degrees, or at least 25 degrees and not more than 75 degrees, or at least 30 degrees and not more than 70 degrees, etc.

[0019] In further examples, each spiral of the plurality of spirals can have at least 2 turns per meter (per meter) along the length of the body, e.g., at least 3 turns per meter, or at least 4 turns per meter, or at least 5 turns per meter, or at least 6 turns per meter, or at least 7 turns per meter. In another aspect, the amount of turns per meter of each spiral can be 10 turns per meter or less, e.g., 9 turns per meter or less, or 8 turns per meter or less. Also, the amount of turns per meter of each spiral can be within a range including any of the minimum and maximum numbers listed above.

[0020] 3 shows a specific example of the shape and position of multiple helices with respect to the central tube, based on one exemplary helix. The helix (31) can contain two helical walls (32) framing an intra-helical channel (33), which may be arranged parallel to each other and run perpendicular (in the y direction) to the length (x direction) of the tube wall (34).

[0021] In certain embodiments, the helical inner channel (33) has a thickness (T C1 In another embodiment, the thickness of the inner spiral channel (T C1 ) may be 125 mm or less, for example, 100 mm or less, or 80 mm or less, or 50 mm or less, or 45 mm or less, or 40 mm or less, or 35 mm or less. C1 ) may be within a range that includes any of the minimum and maximum values ​​listed above.

[0022] In another embodiment, the wall thickness (T WS ) can be at least 1 mm, or at least 1.5 mm, or at least 2 mm, or at least 3 mm, or at least 4 mm. In further embodiments, the thickness of the helical wall (T WS) may be 5 mm or less, or 4 mm or less, or 3.5 mm or less. Furthermore, the wall thickness of the spiral (T WS ) can be within a range that includes any of the minimum and maximum values ​​listed above.

[0023] In further embodiments, the tube (34) surrounding the central cavity has a wall thickness (T WT In another embodiment, the tube wall thickness (T WT The wall thickness of the tube (T WT ) can be within a range that includes any of the minimum and maximum values ​​listed above.

[0024] In yet another embodiment, the height (H S ) may be at least 7.5 mm, or at least 15 mm, or at least 20 mm. In another embodiment, the height of the helix (H S The height of the spiral (H ) may be 43 mm or less, or 40 mm or less, or 35 mm or less. S ) can be within a range that includes any of the minimum and maximum values ​​listed above.

[0025] In another embodiment, the cross-sectional surface area of ​​the helical inner channel (33) is at least 245 mm 2 , or at least 500 mm 2 , or at least 800 mm 2 , or at least 1000 mm 2 , or at least 1200 mm 2 In a further aspect, the cross-sectional area of ​​the inner helical channel can be 1500 mm 2 Less than or equal to 1450mm 2 Less than or equal to 1300mm 2 Additionally, the cross-sectional area of ​​the inner helical channel may be within a range that includes any of the minimum and maximum values ​​listed above.

[0026] In yet another embodiment, the height H of the helical channel C can be at least 6.4 mm, or at least 7.0 mm, or at least 10.0 mm, or at least 15 mm, or at least 20 mm, or at least 25 mm. C may be 38 mm or less, or 35 mm or less, or 30 mm or less. Furthermore, the height H C can be within a range that includes any of the minimum and maximum values ​​listed above.

[0027] 4 shows a cross-section of a side view section of a body with two helices (41) positioned next to each other and attached to a tube wall (44). As mentioned above, the spaces between the helices, referred to herein as inter-helix channels (42), allow for fluid flow down the length of the body.

[0028] In one embodiment, the average thickness (T C2 ) can be at least 3 mm, or at least 4 mm, or at least 5 mm, or at least 10 mm, or at least 15 mm, or at least 20 mm, or at least 25 mm, or at least 30 mm, or at least 40 mm. In another embodiment, the thickness of the inter-spiral channel (T C2 ) may be 50 mm or less, or 45 mm or less, or 40 mm or less, or 35 mm or less, or 30 mm or less, or 20 mm or less. Additionally, the thickness of the inter-spiral channels may be within a range including any of the minimum and maximum values ​​recited above.

[0029] In a further embodiment, the helical wall thickness T WS and the thickness of the inner helical channel T C1 may be 1:1 or less, or 1:5 or less, or 1:10 or less, or 1:15 or less, or 1:20 or less.

[0030] In certain embodiments, the multiple spirals may be disposed parallel to one another.

[0031] In another embodiment, as shown in FIG. 5, each helix (51) of the plurality of helices can have a first straight section (52) at a proximal end and a second straight section (53) at a distal end of the body, where the first straight section (52) and the second straight section (53) are oriented along the length of the body, extending through an inter-helix channel (54).

[0032] 6 shows a cross-section of a section of a heat exchanger insert along its length, according to one embodiment. A central cavity 61 is surrounded by a tube 62 to which multiple spirals (63) may be attached, the spirals containing intra-spiral channels (65) and the spaces between the spirals being inter-spiral channels (64).

[0033] The ceramic of the body of the heat exchanger component can include silicon carbide, a metal, a metal alloy, hi certain embodiments, the ceramic can consist essentially of silicon carbide.

[0034] In a further embodiment, the body material may consist essentially of silicon carbide and have a hardness of at least 2.50 g / cm 3 average density, e.g. at least 2.55 g / cm 3 , or at least 2.57 g / cm 3 , or at least 2.60 g / cm 3 , or at least 2.70 g / cm 3 In a further embodiment, the silicon carbide ceramic body may have an average density of 2.9 g / cm 3 or less than 2.8g / cm 3 or less than 2.75g / cm 3 The average density of the material of the body may be within a range that includes any of the minimum and maximum values ​​listed above.

[0035] In certain embodiments, the body of the heat exchanger component can be manufactured by a powder pressing process, for example, as described in US Pat. No. 8,162,040, the entire disclosure of which is incorporated herein by reference.

[0036] The heat exchanger components of the present disclosure may have a body that may advantageously have an exchange ratio (ER) that provides high heat exchange efficiency. As used herein, exchange ratio is defined as ER=SA / V, where SA is the outer surface area of ​​the body and V is the hollow volume of the body. In one embodiment, the exchange ratio (ER) of the body is at least 39 m -1 , e.g. at least 45m -1 , or at least 50m -1 , or at least 60m -1 , or at least 70m -1 , or at least 80m -1 , or at least 90m -1 , or at least 100m -1 , or at least 110m -1 , or at least 120 m -1 , or at least 130 m -1 , or at least 140 m -1 , or at least 150 m -1 In another embodiment, the exchange rate is 196m -1 Less than or equal to 185m -1 Less than or equal to 180m -1 Less than or equal to 170m -1 The replacement rate (ER) of the main body may be set to a value within a range including any of the minimum and maximum values ​​described above.

[0037] The body of the heat exchanger component of the present invention can withstand a pressure of at least 0.035 MPa anywhere on the body without forming cracks or deformations.

[0038] In one embodiment, the Nusselt Number of the heat exchanger components of the present disclosure may be at least 1000, such as at least 1050, or at least 1100, or at least 1200.

[0039] The body of the heat exchanger component may be adapted to operate at a temperature of at least 450° C., such as at least 500° C., or at least 600° C., or at least 700° C., or at least 800° C., or at least 900° C., or at least 1000° C. In another embodiment, the body may be adapted to operate at a temperature of 1350° C. or less, or 1300° C. or less, or 1200° C. or less, or 1100° C. or less, or 1000° C. or less. Additionally, the body of the heat exchanger may be adapted to operate at a temperature within a range including any of the minimum and maximum values ​​listed above.

[0040] In further embodiments, the heat exchanger components of the present disclosure can be inserted into a system to form a heat exchanger. For example, a heat exchanger insert can be inserted into a mating pipe and connected to a combustion tube via threads.

[0041] The heat exchanger may have at least three flow paths (as described above) and may be adapted to have a pressure drop during operation of 5 kPa or less, for example 4 kPa or less, 3 kPa or less, or 2 kPa or less.

[0042] In an embodiment, a heat exchanger including a heat exchanger component of the present disclosure can have an efficiency of at least 70%, or at least 75%, at least 80%, at least 82%, at least 84%, at least 86%, at least 88%, or at least 90%.

[0043] A heat exchanger containing the heat exchanger insert of the present disclosure has three flow paths and a helix of varying twist angle, allowing the surface area to be maximized in relation to the cross-sectional flow area, thereby achieving low pressure drop (<5 kPa) and extremely high efficiency.

[0044] The heat exchanger components of the present disclosure may further have the advantage that by varying the helix twist angle, the size of the internal channel of the helix (referred to herein as the intra-helical channel) may remain the same and need not be varied along the entire length of the body, thereby simplifying manufacturing and optimizing efficiency.

[0045] Many different aspects and implementations are possible. Some of these aspects and implementations are described herein. After reading this specification, a person skilled in the art will understand that these aspects and implementations are merely illustrative and do not limit the scope of the invention. The implementation may be according to any one or more of the following examples: EXAMPLES

[0046] "Example 1" A component for a heat exchanger having a body comprising a ceramic, the body having a hollow volume adapted for passage of a fluid therethrough, the body having an exchange ratio (ER) of at least 39 m -1 , 196m -1 A component for a heat exchanger, wherein ER=SA / V, where SA is the outer surface area of ​​the body and V is the hollow volume of the body.

[0047] "Example 2" A body comprising ceramic, a central cavity extending along the length of the body; a plurality of spirals extending around a central cavity; a plurality of inter-helical channels disposed between the plurality of helices; A heat exchanger component having a body having A component for a heat exchanger, wherein at least one helix of the plurality of helices has a twist angle that varies along the length of the body.

[0048] "Example 3" 3. The heat exchanger component of example 2, further comprising a plurality of intra-helical channels contained within the plurality of helices.

[0049] "Example 4" 4. The heat exchanger component of claim 2 or 3, wherein each spiral of the plurality of spirals has one intra-helical channel.

[0050] "Example 5" 3. The heat exchanger component of claim 2, wherein each of the plurality of spirals has a twist angle that varies along the length of the body.

[0051] "Example 6" A heat exchanger component as described in any one of Examples 2 to 5, wherein the twist angle has a first twist angle α1 at a proximal end of at least one spiral and a second twist angle α2 at a distal end of at least one spiral, the first twist angle α1 being different from the second twist angle α2.

[0052] "Example 7" 7. The heat exchanger component of embodiment 6, wherein the first twist angle α1 is greater than the second twist angle α2.

[0053] "Example 8" 7. The heat exchanger component of embodiment 6, wherein the first twist angle α1 is smaller than the second twist angle α2.

[0054] "Example 9" A heat exchanger component as described in any one of Examples 2 to 8, wherein the twist angle is at least 15 degrees and no more than 90 degrees throughout the entire length of the body, for example, at least 20 degrees and no more than 80 degrees, or at least 25 degrees and no more than 75 degrees, or at least 30 degrees and no more than 70 degrees.

[0055] "Example 10" The heat exchanger component of any one of Examples 2 to 9, wherein the twist angle increases continuously between the proximal end and the distal end of the body.

[0056] "Example 11" The heat exchanger component of any one of Examples 2 to 9, wherein the twist angle varies discontinuously over the length of the body.

[0057] "Example 12" A heat exchanger component as described in any one of Examples 2 to 11, wherein the twist angle varies by at least 1 degree per 0.1 meter of the body, for example, at least 3 degrees per 0.1 meter, or at least 5 degrees per 0.1 meter, or at least 7 degrees per 0.1 meter, or at least 10 degrees per 0.1 meter, or at least 15 degrees per 0.1 meter, or at least 20 degrees per 0.1 meter.

[0058] "Example 13" The heat exchanger component of any one of Examples 2 to 12, wherein the central cavity is surrounded by a tube and the plurality of spirals are attached to an outer surface of the tube.

[0059] "Example 14" The heat exchanger component of any one of Examples 2 to 13, wherein each spiral of the plurality of spirals has one intra-spiral channel defining a flow path for a fluid passing through the spiral.

[0060] "Example 15" The heat exchanger component of any one of Examples 2 to 14, wherein the plurality of spirals includes at least four spirals, e.g., at least six spirals, at least eight spirals, at least ten spirals, or at least twelve spirals.

[0061] "Example 16" 16. The heat exchanger component of embodiment 15, wherein the plurality of spirals comprises at least 10 spirals.

[0062] "Example 17" 16. The heat exchanger component of any one of Examples 2 to 15, wherein the plurality of spirals comprises 12 or fewer spirals.

[0063] "Example 18" 18. The heat exchanger component of any one of Examples 2 to 17, wherein the spirals are arranged parallel to one another.

[0064] "Example 19" 19. A heat exchanger component as described in any one of Examples 2 to 18, wherein each spiral of the plurality of spirals has at least 2 turns per meter, e.g., at least 3 turns per meter, at least 4 turns per meter, at least 5 turns per meter, at least 6 turns per meter, or at least 7 turns per meter along the length of the body.

[0065] "Example 20" 20. The heat exchanger component of any one of Examples 2 to 19, wherein each spiral of the plurality of spirals has 10 turns per meter or less, or 9 turns per meter or less, or 8 turns per meter or less.

[0066] "Example 21" 21. A heat exchanger component according to any one of Examples 2 to 20, wherein the average wall thickness of the tubes surrounding the central cavity is at least 1 mm, or at least 1.5 mm, or at least 2 mm, or at least 3 mm, or at least 4 mm.

[0067] "Example 22" 22. The heat exchanger component of any one of Examples 2 to 21, wherein the average wall thickness of the tubes surrounding the central cavity is 5 mm or less, or 4.5 mm or less, or 4 mm or less, or 3.5 mm or less.

[0068] "Example 23" A heat exchanger component as described in any one of Examples 2 to 22, wherein each spiral of the plurality of spirals has two spiral walls framing one intra-helical channel, the two spiral walls being positioned parallel to each other and extending perpendicular to the length of the central cavity wall.

[0069] "Example 24" A heat exchanger component as described in any one of Examples 2 to 23, wherein the average thickness of each of the plurality of intra-helical channels is at least 3 mm, or at least 5 mm, or at least 10 mm, or at least 15 mm, or at least 20 mm, or at least 25 mm, or at least 30 mm, or at least 40 mm.

[0070] "Example 25" A heat exchanger component as described in any one of Examples 2 to 24, wherein the average thickness of each of the plurality of intra-helical channels is 50 mm or less, or 45 mm or less, or 40 mm or less, or 30 mm or less, or 20 mm or less.

[0071] "Example 26" A heat exchanger component as described in any one of Examples 2 to 25, wherein the average thickness of each inter-spiral channel is at least 3 mm, or at least 4 mm, or at least 5 mm, or at least 10 mm, or at least 15 mm, or at least 20 mm, or at least 25 mm, or at least 30 mm, or at least 40 mm.

[0072] "Example 27" A heat exchanger component as described in any one of Examples 2 to 26, wherein the average thickness of each inter-spiral channel of the plurality of inter-spiral channels is 50 mm or less, or 45 mm or less, or 40 mm or less, or 35 mm or less, or 30 mm or less, or 20 mm or less.

[0073] "Example 28" 28. The heat exchanger component of any one of Examples 2 to 27, wherein an average thickness of each inter-spiral channel of the plurality of inter-spiral channels varies along the length of the body.

[0074] "Example 29" A heat exchanger component as described in any one of Examples 2 to 28, wherein the ratio of the helical wall thickness TSW of the plurality of helices to the thickness TIC of the plurality of inner helical channels is at least 1:1 and not more than 1:20.

[0075] "Example 30" The average cross-sectional area of ​​each of the plurality of intra-helical channels is at least 245 mm 2 , or at least 250 mm 2 , or at least 300 mm 2 , or at least 500 mm 2 , or at least 1000 mm 2 , or at least 1200 mm 2 30. The heat exchanger component according to any one of Examples 2 to 29, wherein

[0076] "Example 31" The average cross-sectional area of ​​each of the plurality of intra-helical channels is 1470 mm 2 Less than or equal to 1450mm 2 Less than or equal to 1400mm 2 Less than or equal to 1300mm 2 31. A heat exchanger component according to any one of Examples 2 to 30, wherein:

[0077] "Example 32" A heat exchanger component as described in any one of Examples 2 to 31, wherein each spiral of the plurality of spirals has a first straight section at a distal end and a second straight section at a proximal end, the first straight section and the second straight section extending inter-spiral channels and oriented parallel to the longitudinal direction of the body.

[0078] "Example 33" The heat exchanger component of any one of Examples 2 to 32, wherein the ceramic of the body comprises silicon carbide.

[0079] "Example 34" The heat exchanger component of any one of Examples 2 to 33, wherein the ceramic of the body consists essentially of silicon carbide.

[0080] "Example 35" A heat exchanger component as described in any one of Examples 2 to 34, wherein the body can withstand a pressure of at least 0.035 MPa at any location on the body without cracking or deformation.

[0081] "Example 36" The material of the body comprises silicon carbide and the average density of the material is at least 2.50 g / cm 3 , or at least 2.55 g / cm 3 , or at least 2.57 g / cm 3 , or at least 2.60 g / cm 3 , or at least 2.70 g / cm 3 , or at least 2.80 g / cm 3 The heat exchanger component according to any one of Examples 2 to 35, wherein

[0082] "Example 37" The material of the body is silicon carbide, and the average density of the material is 3.05 g / cm 3 For example, 3.0 g / cm 3 Below, 2.9g / cm 3 Below, 2.8g / cm 3 Below, 2.7g / cm 3 or less than 2.6g / cm 3 37. A heat exchanger component according to any one of Examples 2 to 36, wherein:

[0083] "Example 38" The heat exchanger component of any one of Examples 2 to 37, wherein the body has a Nusselt Number of at least 1000, e.g., at least 1050, at least 1100, or at least 1200.

[0084] "Example 39" The heat exchanger component of any one of Examples 2 to 38, wherein the body is adapted to operate at a temperature of at least 450°C, such as at least 500°C, or at least 600°C, or at least 700°C, or at least 800°C, or at least 900°C, or at least 1000°C.

[0085] "Example 40" The heat exchanger component of any one of Examples 2 to 39, wherein the body is adapted to operate at a temperature of 1350°C or less, or 1300°C or less, or 1200°C or less, or 1100°C or less, or 1000°C or less.

[0086] "Example 41" A heat exchanger having a heat exchanger component of any one of Examples 2 to 40, wherein the heat exchanger is adapted to have a pressure drop during operation of 5 kPa or less, e.g., 4 kPa or less, or 3 kPa or less.

[0087] "Example 42" A heat exchanger having the heat exchanger component of any one of Examples 2 to 40, wherein the heat exchanger is adapted to conduct a fluid flow of a gas, a liquid, or a combination thereof.

[0088] "Example 43" 43. The heat exchanger of embodiment 42, adapted to direct a gas flow.

[0089] "Example 44" 44. The heat exchanger of any one of examples 41 to 43 having three flow paths.

[0090] "Example 45" The heat exchanger of any one of Examples 41 to 44, wherein the efficiency of the heat exchanger is at least 85%, e.g., at least 86%, at least 87%, at least 88%, at least 89%, or at least 90%.

[0091] In the foregoing specification, the concepts have been described with reference to specific embodiments. However, those skilled in the art will understand that various modifications and changes can be made without departing from the scope of the invention as set forth in the following claims. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the invention.

Claims

1. 1. A heat exchanger component adapted as an insert for use in a radiant tube, comprising: A body comprising ceramic, a central cavity extending along the length of said body; a plurality of helical features extending around the central cavity; a plurality of inter-helical channels disposed between the plurality of helical features; at least one helical feature of the plurality of helical features has a twist angle that varies along a length of the body, the twist angle being an angle of the helical feature inclined from a longitudinal axis of the body; each helical feature of the plurality of helical features includes a first straight section at a proximal end and a second straight section at a distal end, the first straight section and the second straight section of each inter-helical channel extending through the inter-helical channel and oriented parallel to a length of the body; The body is configured to return a portion of a fluid flowing through the inner helical channel back through the central cavity to the distal end.

2. The heat exchanger component of claim 1 , wherein each helical feature of the plurality of helical features has an intra-helical channel.

3. The heat exchanger component of claim 1 , wherein each helical feature of the plurality of helical features has a varying twist angle along a length of the body.

4. The heat exchanger component of claim 1 , wherein the twist angle is at least 15 degrees.

5. 2. The heat exchanger component of claim 1, wherein the twist angle varies by at least 1 degree per 0.1 meter along the length of the body.

6. The heat exchanger component of claim 1 , wherein the central cavity is surrounded by a tube, and the plurality of helical features are attached to an exterior surface of the tube.

7. The heat exchanger component of claim 1 , wherein the plurality of helical features comprises at least four helical features.

8. The heat exchanger component of claim 1 , wherein each helical feature of the plurality of helical features has at least 2 turns per meter and no more than 10 turns per meter along the length of the body.

9. The average cross-sectional area of ​​each intra-helical channel of the plurality of helical features is at least 245 mm ２ 3. The heat exchanger component of claim 2, wherein:

10. The material of the body comprises silicon carbide and has an average density of at least 2.50 g / cm ３ 2. The heat exchanger component of claim 1, wherein:

11. The heat exchanger component of claim 1 , wherein the body is operable at a temperature of at least 450° C.

12. 10. A heat exchanger having the heat exchanger component of claim 1, adapted to provide a fluid pressure drop in a fluid flow path of the heat exchanger during operation of 5 kPa or less.

13. A heat exchanger as described in claim 12, having three flow paths including the central cavity, the inter-spiral channel, and the intra-spiral channel.

14. 1. A heat exchanger component adapted as an insert for use in a radiant tube, the heat exchanger component having a body comprising a ceramic, the heat exchanger comprising: the body having a hollow volume adapted to allow a fluid to pass through the body; The exchange rate (ER) of the body is at least 39m －１ , and 196m －１ is as follows: where SA is the outer surface area of ​​the body and V is the hollow volume of the body, ER=SA / V; The body includes: a central cavity extending along the length of said body; a plurality of helical features extending around the central cavity; a plurality of inter-helical channels disposed between the plurality of helical features; each helical feature of the plurality of helical features includes a first straight section at a proximal end and a second straight section at a distal end, the first straight section and the second straight section of each inter-helical channel extending through the inter-helical channel and oriented parallel to a length of the body; The body is configured to return a portion of a fluid flowing through the inner helical channel through the central cavity to the distal end.

15. 15. The heat exchanger component of claim 14, wherein each helical feature of the plurality of helical features has a twist angle that varies along a length of the body, the twist angle being the angle of the helical feature tilted from a longitudinal axis of the body.

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