Vertical rod baffle heat exchanger system and method

Abstract

The vertical rod baffle heat exchanger can be used in industrial applications such as heat removal, condensation operations, power generation, petrochemical plants, and waste heat recovery. The vertical rod baffle heat exchanger may include a shell, a tube sheet, a tube bundle having a plurality of axially extending heat exchange tubes, six or more vertical partition plates, and a plurality of rod baffle rings arranged along the axial length of the plurality of heat exchange tubes. At least one vertical partition plate may be a cut-out vertical partition plate. The plurality of rod baffle rings may include horizontal rod baffles and vertical rod baffles. The horizontal rod baffles and the vertical rod baffles may pass through gaps between every two adjacent tubes of the plurality of heat exchange tubes. The horizontal rod baffles may pass through openings in the cut-out vertical partition plate.

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE Embodiments disclosed herein relate generally to heat exchanger systems. More particularly, embodiments disclosed herein relate to vertical rod baffle heat exchangers for reaction heat removal. [Background technology]

[0002] Rod baffle heat exchangers were created by Philips Petroleum Company in 1970 to eliminate flow-induced vibration in plate baffle heat exchangers. Rod baffle heat exchangers are shell-and-tube type heat exchangers that utilize rod baffles to support and secure the tubes against vibration. Additionally, rod baffles can be used to modify the shell-side flow distribution to make the shell-side flow more turbulent. "Baffle" refers to an annular ring with multiple support rods connected at their ends (hence "rod baffle"). Examples of rod baffle heat exchangers can be found, for example, in U.S. Pat. No. 5,642,778 and Chinese Patent No. 104197751, which are incorporated herein by reference.

[0003] As shown in FIG. 1, a conventional rod baffle heat exchanger, such as shell-and-tube heat exchanger 10, can include a rod baffle tube bundle 12 surrounded by a shell 14. Tubes 28 in the tube bundle 12 are supported by a plurality of rod baffle assemblies 16, 18, 20, and 22. A fluid enters the shell side of the shell-and-tube heat exchanger 10 at an inlet 26, exchanges heat with the fluid in the tubes 28, and exits the shell side via an outlet 30. Fluid flowing through the tube side of the heat exchanger enters the heat exchanger's end cap 38 at an inlet 32 ​​and exits the heat exchanger's end cap 44 via an outlet 34. Thus, fluid flows from an end chamber 36 defined by the end cap 38 and tube sheet 40 of the heat exchanger 10, through the tubes 28, and into an opposite end chamber 42 also defined by the end cap 44 and another tube sheet 46. Summary of the Invention [Means for solving the problem]

[0004] This Summary is provided to introduce a selection of concepts that are further described below in the Detailed Description. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

[0005] In one aspect, the embodiments disclosed herein relate to a vertical rod baffle heat exchanger that can be used in industrial applications such as heat removal, condensation operations, power generation, petrochemical plants, waste heat recovery, etc. The vertical rod baffle heat exchanger may include a shell, a tube sheet, a tube bundle having a plurality of axially extending heat exchange tubes, the tube bundle being a U-shaped tube bundle that may have U-bends in the heat exchange tubes, six or more vertical dividers, at least one of which is a cut-out vertical divider, and a plurality of rod baffle rings disposed along the axial length of the plurality of heat exchange tubes, the plurality of rod baffle rings may have transverse rod baffles and longitudinal rod baffles. The transverse rod baffles and longitudinal rod baffles may pass through gaps between every two adjacent tubes of the plurality of heat exchange tubes, and the transverse rod baffles may pass through openings in the cut-out vertical dividers. The cut-out vertical dividers may extend a longitudinal length of at least the lower end of the U-shaped tube bundle to provide a lower liquid seal. The notched mullion may extend a radial length with a notched end of the notched mullion within the U-tube bundle.

[0006] In one or more embodiments, the vertical rod baffle heat exchanger may further include a plurality of support bars arranged on the circumference of the shell adapted to secure the tube bundle and provide a slideway for the plurality of rod baffle rings. The plurality of support bars may be spaced apart from one another and rotated 90 degrees around the circumference of the plurality of rod baffle rings. A non-condensable gas outlet may be provided on the shell near the tubesheet at a similar level to the steam inlet. A liquid cylinder may be provided near the elbow on the shell side. An impingement plate may be provided on the shell to distribute steam entering from the inlet.

[0007] In some embodiments, the plurality of rod baffle rings may include a set of four rod baffle rings, a first rod baffle ring having a plurality of transverse rod baffles extending from an inner surface of the first rod baffle ring, a second rod baffle ring having a plurality of longitudinal rod baffles extending from an inner surface of the second rod baffle ring, a third rod baffle ring having a plurality of transverse rod baffles extending from an inner surface of the third rod baffle ring, and a fourth rod baffle ring having a plurality of longitudinal rod baffles extending from an inner surface of the fourth rod baffle ring. The vertical rod baffle heat exchanger may include at least four sets of four rod baffle rings. Additionally, a fifth set of four rod baffle rings may include two of the first rod baffle ring, the third rod baffle ring, and the fourth rod baffle ring. Each of the plurality of rod baffle rings may be equally spaced apart from adjacent rod baffles over the length of the U-tube bundle. Each of the six or more vertical partitions may be a notched vertical partition. Each of the vertical partitions may have a width of 3 to 9 millimeters.

[0008] In yet another embodiment, the distance between the mullions and the length of the cut out mullions may vary. The distance between the first mullions and the second mullions may be greater than the distance between the second mullions and the third mullions. The distance between the second mullions and the third mullions may be greater than the distance between the third mullions and the fourth mullions. The distance between the third mullions and the fourth mullions may be greater than the distance between the fourth mullions and the fifth mullions. The distance between the fourth mullions and the fifth mullions may be greater than the distance between the fifth mullions and the sixth mullions. The cut out end of each cut out mullions may be vertically spaced apart from the shell. The vertical distance of the cut out mullions may decrease from the first mullions to the sixth mullions.

[0009] Other aspects and advantages will become apparent from the following description and the appended claims. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 shows a side elevation view of a shell-and-tube heat exchanger according to the prior art. [Diagram 2] FIG. 1 illustrates a top view of a rod baffle heat exchanger according to one or more embodiments of the present disclosure. [Diagram 3] FIG. 1 illustrates a perspective view of multiple rod baffle rings of a rod baffle heat exchanger in accordance with one or more embodiments of the present disclosure. [Figure 4] FIG. 2 illustrates a partial close-up top view of multiple tubes of a rod baffle heat exchanger in accordance with one or more embodiments of the present disclosure. [Diagram 5] FIG. 1 illustrates a partial view of a rod baffle heat exchanger according to one or more embodiments of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Hereinafter, the embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Similar elements in various drawings may be designated with similar reference numerals for consistency. Furthermore, in the following detailed description, numerous specific details are set forth to enable a fuller understanding of the claimed subject matter. However, it will be apparent to one skilled in the art that the described embodiments may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. As used herein, "coupled" or "coupled to" or "connected" or "connected" may indicate establishing either a direct or indirect connection, and is not limited to either, unless expressly stated as such. As used herein, fluid may refer to a slurry, liquid, gas, and / or mixtures thereof. Wherever possible, similar or identical reference numerals are used in the drawings to identify common or identical elements. The drawings are not necessarily to scale, and certain features and certain figures of the drawings may be shown exaggerated in scale for clarity.

[0012] In one aspect, the embodiments disclosed herein relate to rod baffle heat exchangers for industrial applications such as heat removal, condensation operations, power generation, petrochemical plants, waste heat recovery, etc. The rod baffle heat exchanger may also be interchangeably referred to as a rod baffle condenser in this disclosure. Additionally, the rod baffle heat exchanger may incorporate a vertical partition plate in the vertical baffle. The rod baffle heat exchanger may assist in the removal of polymerization heat in the cooling loop. Additionally, the rod baffle heat exchanger may enable higher condensation efficiency compared to conventional condensers.

[0013] Conventional rod baffle heat exchangers in industrial applications are usually very large and heavy because they are horizontally positioned. Moreover, conventional vertical rod baffle heat exchangers use smaller and shorter vertical baffle plates. Conventional vertical rod baffle heat exchangers are not sufficient for modern polymerization reactors that are larger in size and capacity. For example, conventional vertical rod baffle heat exchangers may cause the liquid level to be too low when the size and capacity are increased, which then causes shutdown due to steam flow shortcut.

[0014] Thus, one or more embodiments of the present disclosure may be used to overcome such challenges and provide additional advantages over conventional rod baffle heat exchangers, as would be apparent to one of ordinary skill in the art. In one or more embodiments, the rod baffle heat exchanger may increase the gas velocity around the tubes in the rod baffle heat exchanger, increasing the operating range in terms of heat exchange coefficient. According to embodiments herein, the rod baffle heat exchanger may include an extended baffle plate to allow for a lower liquid level and an extended operating range for the polymerization process. In one or more embodiments, the extended longitudinal baffle plate may reduce the risk of plant shutdowns when cooling water temperatures change unexpectedly, allowing the plant to operate at higher capacity. The placement of the rod baffles in the heat exchanger provides improved vibration protection, with the rod baffles being more evenly distributed. Additionally, the rod baffle heat exchanger may increase reliability and performance over the operating cycle. Overall, the rod baffle heat exchanger may minimize the risks associated with product engineering, rod baffle manufacturing, reduced assembly time, reduced hardware costs, and reduced weight and packaging materials.

[0015] According to embodiments herein, the rod baffle heat exchanger may include multiple longitudinal baffle plates to increase steam velocity and make heat transfer more efficient. In a non-limiting example, the rod baffle heat exchanger may have six longitudinal baffle plates. In one or more embodiments, the support of the transverse and longitudinal rods of the rod baffle heat exchanger may be split to provide a more even distribution to improve vibration isolation. Additionally, the length of the longitudinal baffle plates may be increased to cover at least the entire length of the U-bundle to maintain liquid seal at low levels and increase operating flexibility.

[0016] In one or more embodiments, the rod baffle heat exchanger may be a vertical rod baffle condenser having one or more extended vertical dividers, such as six or more extended vertical dividers. The extended vertical dividers can increase the condensation efficiency of the vertical rod baffle condenser by increasing the gas velocity around the tubes. Additionally, the extended vertical dividers can increase the operating range in terms of heat exchange coefficient due to the extended baffle plates allowing a lower liquid level.

[0017] Referring to FIG. 2, FIG. 2 illustrates a top view of a rod baffle heat exchanger 100 according to one or more embodiments of the present disclosure. The rod baffle heat exchanger 100 may include six or more vertical dividers 101. The six or more vertical dividers 101 may be inserted into a tube bundle 102 of the rod baffle heat exchanger 100. The tube bundle 102 is surrounded by a shell 103. A number of instrument nozzles 120 may be disposed around the shell 103. The instrument nozzles 120 may provide various measurements in the rod baffle heat exchanger 100, such as level measurements, temperature measurements, and the like in the rod baffle heat exchanger 100. Additionally, a tube sheet 119 may be disposed on the six or more vertical dividers 101. In one or more embodiments, the distance D between the vertical dividers 101 may vary. In a non-limiting example, the distance D between the first vertical partition 101a and the second vertical partition 101b may be greater than the distance between the second vertical partition 101b and the third vertical partition 101c. The distance between the second vertical partition 101b and the third vertical partition 101c may be greater than the distance between the third vertical partition 101c and the fourth vertical partition 101d. The distance between the third vertical partition 101c and the fourth vertical partition 101d may be greater than the distance between the fourth vertical partition 101d and the fifth vertical partition 101e. The distance between the fourth vertical partition 101d and the fifth vertical partition 101e may be greater than the distance between the fifth vertical partition 101e and the sixth vertical partition 101f. It is further envisaged that the width W of each of the vertical partitions 101 has a value between 3 and 9 mm, for example a value of 8 mm.

[0018] In one or more embodiments, one or more of the six or more vertical dividers 101 may be cut-out vertical dividers 104 disposed in the tube bundle 102. Each of the cut-out vertical dividers 104 may have a cut-out end 105 at a vertical distance Dn from the shell 103. Each of the cut-out vertical dividers 104 may have a varying vertical distance Dn. The vertical distance Dn of the cut-out vertical dividers 104 may decrease from the first vertical divider 101a to the sixth vertical divider 101f. In a non-limiting example, the vertical distance Dn of the first vertical divider 101a may be greater than the vertical distance of the second vertical divider 101b. The vertical distance of the second vertical divider 101b may be greater than the vertical distance of the third vertical divider 101c. The vertical distance of the third vertical divider 101c may be greater than the vertical distance of the fourth vertical divider 101d. The vertical distance of the fourth vertical divider 101d may be greater than the vertical distance of the fifth vertical divider 101e. The vertical distance of the fifth vertical divider 101e may be greater than the vertical distance of the sixth vertical divider 101f. In some embodiments, the value of the vertical distance Dn is selected so that there is a sufficient area between the cutout vertical divider 104 and the shell 103 for steam to pass to the next divider. Furthermore, each cutout end 105 may orient adjacent cutout vertical dividers 104 180 degrees such that each adjacent cutout vertical divider 104 terminates in the opposite direction from the shell 103.

[0019] 2, the outlet 107 may be provided on the shell 103 at a similar level (circumferential position) as the inlet 108, close to the tube sheet 119. In some embodiments, the outlet 107 may be a non-condensable gas outlet, and the inlet 108 may be a steam inlet. From the inlet 108, steam may enter the rod baffle heat exchanger 100 and flow through a flow path (see block arrow F) defined by six or more vertical dividers 101, and exit from the outlet 107. Furthermore, a liquid-filled cylindrical portion 109 may be provided below the elbow portion 109a of the rod baffle heat exchanger 100 on the shell 103. The elbow portion 109a may be a part of the shell 103 that forms the outlet 107 and the inlet 108. Furthermore, an impingement plate 110 may be provided on the shell 103 to distribute the steam entering from the inlet 108.

[0020] In some embodiments, the tubes 106 may extend axially within the tube bundle 102 such that six or more vertical dividers 101 separate the tubes 106 of the tube bundle 102. In one or more embodiments, the tube bundle 102 may be a U-shaped tube bundle such that the tubes 106 have bends. It is further envisioned that the cut-out vertical divider 104 extends a radial length such that the cut-out end 105 is within the tube bundle 102. The radial length of the cut-out vertical divider 104 may be measured from the end attached to the shell 103 to the cut-out end 105. The minimum vertical length of the cut-out vertical divider 104 is greater than the lowest point at which the tubes 106 are disposed within the U-shaped tube bundle 102. By extending the cut-out vertical divider 104 vertically at least to the end of the U-shaped tube bundle, a lower liquid seal is obtained and the operating range of the rod baffle heat exchanger 100 is increased.

[0021] As shown in FIG. 3, in one or more embodiments, the rod baffle heat exchanger 100 may include multiple rod baffle rings 111, 112, 113, 114 distributed along the axial axis Ax of the multiple tubes (see 106 in FIG. 2). For illustrative purposes only, FIG. 3 is shown with four rod baffle rings 111, 112, 113, 114, but the rod baffle heat exchanger 100 may have any number of rod baffle rings without departing from the scope of the present disclosure. Additionally, multiple support bars 115 may be disposed around the circumference of the shell (see 103 in FIG. 2), which may be used to secure the tube bundle (see 102 in FIG. 2) and may act as slideways for the multiple rod baffle rings 111, 112, 113, 114. In a non-limiting example, the rod baffle heat exchanger 100 may have four support bars 115 evenly spaced such that the support bars 115 are at 90 degree increments around the circumference of the multiple rod baffle rings 111, 112, 113, 114.

[0022] In one or more embodiments, the rod baffle rings 111, 112, 113, 114 may be provided in a set of four. The rod baffle rings 111, 112, 113, 114 may be configured such that each rod baffle ring is rotated 90 degrees from an adjacent rod baffle ring. By staggering the rod baffle rings 111, 112, 113, 114 90 degrees back and forth, the rod baffle heat exchanger 100 can eliminate pooling and achieve high flux flow of condensate on the tubes (see 106 in FIG. 2). In a non-limiting example, the first rod baffle ring 111 in the set of four rod baffle rings may have a plurality of transverse rod baffles 111a extending from an inner surface 111b of the first rod baffle ring 111. A second rod baffle ring 112 in the set of four rod baffle rings may have a plurality of longitudinal rod baffles 112a extending from an inner surface 112b of the second rod baffle ring 112. A third rod baffle ring 113 in the set of four rod baffle rings may have a plurality of transverse rod baffles 113a extending from an inner surface 113b of the third rod baffle ring 113. A fourth rod baffle ring 114 in the set of four rod baffle rings may have a plurality of longitudinal rod baffles 114a extending from an inner surface 114b of the fourth rod baffle ring 114.

[0023] Referring now to FIG. 4, in one or more embodiments, FIG. 4 shows a partial close-up top view of multiple tubes 106 spaced apart by horizontal rod baffles 111a, 113a of first and third rod baffle rings 111, 113 and vertical rod baffles 112a, 114a of second and fourth rod baffle rings 112, 114.

[0024] As shown in FIG. 4, the horizontal rod baffles 111a and 113a close the gap 11 between the tubes (106) adjacent to each other in the X-axis direction. 6a The vertical rod baffles 112a and 11 4 a is the gap 116 between adjacent tubes (106) in the Y-axis directionb Additionally, the transverse rod baffles 111a, 113a may pass through openings in the cut out vertical dividers (see 104 in FIG. 2). By increasing the distance between the transverse and vertical rods, the flow of liquid condensate in the plurality of tubes 106 may be less restricted and support for the plurality of tubes 106 may be more evenly distributed over the length of the plurality of tubes 106.

[0025] Referring now to FIG. 5, in one or more embodiments, FIG. 5 illustrates a partial view of a rod baffle heat exchanger 100. As shown in FIG. 5, the plurality of tubes 106 may be in a tube bundle 102, such as a U-shaped tube bundle extending a length L. One skilled in the art would understand how the U-shaped tube bundle 102 allows the plurality of tubes 106 to be bent, such as a U-bend 118, such that the overall length of the plurality of tubes 106 is greater than the length L of the U-shaped tube bundle 102. This allows the rod baffle heat exchanger 100 to have longer tubes 106 while remaining compact, reducing the overall footprint of the rod baffle heat exchanger 100. Additionally, the inlet 108 is at the top of the front side of the tube bundle 102, while the outlet 107 is at the back side of the tube bundle 102. It is further envisioned that the outlet 107 has a smaller diameter than the inlet 108.

[0026] 5, in one or more embodiments, the rod baffle heat exchanger 100 may include four sets of four rod baffle rings 111, 112, 113, 114 as illustrated in FIG. 3 such that there are eight sets of rod baffle rings with horizontal rods and eight sets of rod baffle rings with vertical rods. Additionally, the rod baffle heat exchanger 100 may include a fifth set of four rod baffle rings configured with two first rod baffle rings such that the order of the rod baffle rings is 111, 111, 113, 114 from the U-bend 118 in the U-tube bundle 102. It is further envisioned that the lowest point of the U-bend 118 coincides with the lowest rod baffle ring in the rod baffle heat exchanger 100. Each of the rod baffle rings 111, 112, 113, 114 may be spaced a distance Drb from an adjacent rod baffle such that the rod baffle rings 111, 112, 113, 114 are equally spaced across the length L of the U-tube bundle. Additionally, each of the rod baffle rings 111, 112, 113, 114 may have a thickness T such that the rod baffle rings have a uniform thickness. It is further envisioned that the aft portion 117 of the U-tube bundle has an anti-vibration grid structure.

[0027] While the present disclosure has been described with respect to a limited number of embodiments, those skilled in the art having the benefit of this disclosure will recognize that other embodiments may be devised without departing from the scope of the present disclosure as described herein. Accordingly, the scope of the present disclosure should be limited only by the appended claims.

Claims

1. A shell through which steam and / or non-condensable gas flows; A tube sheet; a tube bundle having a plurality of heat exchange tubes extending in an axial direction, the tube bundle being a U-shaped tube bundle including U-bends in the plurality of heat exchange tubes; Six or more vertical dividers extending vertically in a radial direction of the shell, at least one of the vertical dividers being a notched vertical divider having a notched end at a vertical distance Dn from the shell; a plurality of rod baffle rings provided along an axial length of the plurality of heat exchange tubes, the plurality of rod baffle rings having horizontal rod baffles extending in a radial X-axis direction and vertical rod baffles extending in a radial Y-axis direction; 1. A vertical rod baffle heat exchanger comprising: The horizontal rod baffle and the vertical rod baffle pass through a gap between every two adjacent tubes of the plurality of heat exchange tubes, and the horizontal rod baffle passes through an opening of the cutout vertical partition plate, a lower liquid seal is formed within the shell, and the at least one notched vertical partition plate extends with an axial length longer than a lowest point at which the tubes of the plurality of heat exchange tubes are disposed within the U-tube bundle such that a liquid level of the lower liquid seal is formed at a position axially higher than a lower end of the at least one notched vertical partition plate; a vertical rod baffle heat exchanger wherein the notched vertical dividers extend a radial length having notched ends within the tube bundle.

2. 2. The vertical rod baffle heat exchanger of claim 1, further comprising a plurality of support bars disposed circumferentially on the shell adapted to secure the tube bundles and provide slideways for the plurality of rod baffle rings.

3. 3. The vertical rod baffle heat exchanger of claim 2, wherein the support bars are spaced apart from one another and rotated 90 degrees around the circumference of the rod baffle rings.

4. 2. The vertical rod baffle heat exchanger of claim 1, further comprising a non-condensable gas outlet disposed on said shell near said tubesheet at a similar level to the steam inlet.

5. A part of the shell forming the steam inlet and the non-condensable gas outlet forms an elbow portion, The elbow portion is a flow path for passing steam and / or non-condensable gas, 5. The vertical rod baffle heat exchanger of claim 4, further comprising a liquid-sealed cylindrical portion disposed adjacent the elbow portion.

6. 5. The vertical rod baffle heat exchanger of claim 4, further comprising an impingement plate mounted to the shell for distributing steam entering through the steam inlet.

7. The plurality of rod baffle rings are a first rod baffle ring having a plurality of transverse rod baffles extending from an inner surface of the first rod baffle ring; a second rod baffle ring having a plurality of longitudinal rod baffles extending from an inner surface of the second rod baffle ring; a third rod baffle ring having a plurality of transverse rod baffles extending from an inner surface of the third rod baffle ring; a fourth rod baffle ring having a plurality of longitudinal rod baffles extending from an inner surface of the fourth rod baffle ring; 2. The vertical rod baffle heat exchanger of claim 1, comprising a set of four rod baffle rings each having a diameter of about 100 mm.

8. 8. The vertical rod baffle heat exchanger of claim 7, further comprising at least four sets of four rod baffle rings.

9. 9. The vertical rod baffle heat exchanger of claim 8, further comprising a fifth set of four rod baffle rings including two of the first rod baffle ring, the third rod baffle ring, and the fourth rod baffle ring.

10. 2. The vertical rod baffle heat exchanger of claim 1, wherein each of the plurality of rod baffle rings is equally spaced a distance from an adjacent rod baffle along the length of the U-tube bundle.

11. 2. The vertical rod baffle heat exchanger of claim 1, wherein each of the six or more vertical dividers is a notched vertical divider.

12. 2. The vertical rod baffle heat exchanger of claim 1, wherein each of said vertical dividers has a width of 3 to 9 millimeters.

13. 2. The vertical rod baffle heat exchanger of claim 1, wherein the distance between said vertical dividers and the length of said at least one cut-out vertical divider vary.

14. a distance between the first vertical partition plate and the second vertical partition plate is greater than a distance between the second vertical partition plate and the third vertical partition plate; a distance between the second vertical partition plate and the third vertical partition plate is greater than a distance between the third vertical partition plate and the fourth vertical partition plate; a distance between the third vertical partition plate and the fourth vertical partition plate is greater than a distance between the fourth vertical partition plate and the fifth vertical partition plate; 14. The vertical rod baffle heat exchanger of claim 13, wherein a distance between the fourth vertical divider and the fifth vertical divider is greater than a distance between the fifth vertical divider and the sixth vertical divider.

15. 15. The vertical rod baffle heat exchanger of claim 14, wherein a cut-out end of each cut-out vertical partition is vertically spaced from the shell, and the vertical distance of the cut-out vertical partitions decreases from the first vertical partition to the sixth vertical partition.

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