High temperature heat exchanger with removable heater bundles

Abstract

A heat exchanger including resistive heaters, standoff conduits, and electrical conductors. Each resistive heater includes a heating element conduit and a resistive heating element. The heating element conduit includes fluid flowing therethrough. The resistive heating element is disposed within the heating element conduit. Each standoff conduit is disposed at an end of the heat exchanger opposite the resistive heater and is configured to provide thermal isolation and convective cooling from extreme process temperatures and be coupled to an electrical enclosure through means of an electrically isolating compression fitting feature, thereby accomplishing pressure boundary requirements and enabling easy field replacement of the element by end users. Each of the standoff conduits has an axial end that is fluidly sealed. Each electrical conductor extends through a respective standoff conduit and has a first end electrically coupled to a power supply and a second end electrically coupled to a respective resistive heater.

Description

HIGH TEMPERATURE HEAT EXCHANGER WITH REMOVABLE HEATERBUNDLESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. provisional application number 63 / 553,415 filed February 14, 2024. The disclosure of the above application is incorporated herein by reference in its entirety.FIELD

[0002] The present disclosure relates to electric heaters, and more particularly to high temperature electric heat exchangers.BACKGROUND

[0003] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0004] Heat exchangers generally include a tubular vessel and a plurality of resistive heaters disposed inside the tubular vessel. Each resistive heater includes at least one resistive heating element. Working fluid enters the tubular vessel at one longitudinal end and exits at the other longitudinal end. The working fluid is heated by the resistive heating elements as the working fluid flows inside the tubular vessel. In some heat exchangers, there exists a heated section where the working fluid flows through the fluid vessel and a non-heated section where the working fluid is not heated.

[0005] In order to repair or replace one or more of the heating elements in such heat exchanger, the heat exchanger is disassembled and individual or all heating elements are severed or cut off to gain access to the heating element(s) needing repairing or replacing. Such a repair is time consuming and can lead to undesirable down-time of the heat exchanger.

[0006] These issues related to the repair of heating elements used within fluid heat exchangers, among other issues related to heat exchangers, are addressed by the present disclosure.SUMMARY

[0007] This section provides a general summary of the disclosure and isnot a comprehensive disclosure of its full scope or all of its features.

[0008] In one form, the present disclosure provides a heat exchanger including resistive heaters, standoff conduits and electrical conductors. The resistive heaters are disposed at a first end of the heat exchanger. Each resistive heater includes a heating element conduit and a resistive heating element. The heating element conduit includes fluid flowing therethrough. The resistive heating element is disposed within the heating element conduit. The standoff conduits are disposed at an opposing second end of the heat exchanger and are configured to be coupled to an electrical enclosure. Each of the standoff conduits having an axial end that is fluidly sealed. Each electrical conductor extends through a respective standoff conduit and has first and second ends. The first end is electrically coupled to a power supply and the second end is electrically coupled to a respective resistive heater.

[0009] In variations of the heat exchanger of the above paragraph, which can be implemented individually or in any combination: the heating element conduits are made of a ceramic material and the standoff conduits are made of a metal material; each of the electrical conductors of the electrical conductors comprises a first electrical conductor and a second electrical conductor that are electrically coupled to each other; the second electrical conductor is electrically coupled to the respective resistive heater by crimping, welding, or a push-in retention coupling feature; the first electrical conductor is electrically coupled to the second electrical conductor by crimping, welding, or a push-in retention coupling feature; a plurality of conductor conduits spaced apart from the standoff conduits, the first electrical conductor extends through a respective standoff conduit and the second electrical conductor extends through a respective conductor conduit; at least one heat shield is secured to the plurality of conductor conduits; a pressure retaining flange, a heated section is disposed on one side of the pressure retaining flange and a non-heated section is disposed on an opposite side of the pressure retaining flange; each of the standoff conduits of the plurality of standoff conduits extends substantially through the pressure retaining flange and includes another end that is secured to the pressure retaining flange; the electrical enclosure, the axial end of the standoff conduit is within the electrical enclosure; at least one support disposed within the heating element conduit; the support includes one or more apertures; the support is non-electrically conductive; a central core extending through the heating element conduit and supporting the resistive heating element, each support mechanically coupled to the central core.

[0010] In another form, the present disclosure provides a heat exchanger including resistive heaters, standoff conduits and electrical conductors. The resistive heaters are disposed at a first end of the heat exchanger. Each resistive heater includes a heating element conduit and a resistive heating element. The heating element conduit includes fluid flowing therethrough. The resistive heating element is disposed within the heating element conduit. The standoff conduits are disposed at an opposing second end of the heat exchanger and are configured to be coupled to an electrical enclosure. Each of the standoff conduits is aligned concentrically with each other the resistive heating elements and has an axial end that is fluidly sealed. Each electrical conductor includes a first electrical conductor and a second electrical conductor. The first electrical conductor extends through a respective standoff conduit and has first and second ends. The first end is electrically coupled to a power supply. The second electrical conductor has third and fourth ends. The third end of the second electrical conductor is electrically coupled to the second end of the first electrical conductor and the fourth end of the second electrical conductor is electrically coupled to a respective resistive heater at a location within the heating element conduit.

[0011] In variations of the heat exchanger of the above paragraph, which can be implemented individually or in any combination: the plurality of heating element conduits are made of a ceramic material and the plurality of standoff conduits are made of a metal material; the third end of the second electrical conductor is electrically coupled to the second end of the first electrical conductor by crimping, the fourth end of the second electrical conductor is electrically coupled to the respective resistive heater by crimping; a plurality of conductor conduits are spaced apart from the plurality of standoff conduits, the first electrical conductor extends through the respective standoff conduit and the second electrical conductor extends through the respective conductor conduit; at least one heat shield is secured to the plurality of conductor conduits; at least one support disposed within the heating element conduit and configured to support the resistive heating element; the support disposed within the heating element conduit; the support includes one or more apertures; the support is non-electrically conductive; a central core extending through the heating element conduit and supporting the resistive heating element, each support mechanically coupled to the central core.

[0012] In yet another form, the present disclosure provides a heat exchanger including a pressure retaining flange, a heated section, and a non-heatedsection. The heated section is disposed on one side of the pressure retaining flange and includes resistive heaters. Each resistive heater includes a heating element conduit and a resistive heating element. The heating element conduit includes fluid flowing therethrough. The resistive heating element is disposed within the heating element conduit. The non-heated section is disposed on an opposite side of the pressure retaining flange and includes standoff conduits and electrical conductors. Each standoff conduit has a first axial end and a second axial end. The first axial end of each of the standoff conduits is fluidly sealed. The second axial end of each of the standoff conduits is secured to the pressure retaining flange. The electrical conductors extend through respective standoff conduits and having third and fourth ends. The third end is electrically coupled to a power supply and the fourth end is electrically coupled to a respective resistive heater.

[0013] In variations of the heat exchanger of the above paragraph, which can be implemented individually or in any combination: an electrical enclosure, the first axial end of the standoff conduit is within the electrical enclosure; the plurality of heating element conduits are made of a ceramic material and the plurality of standoff conduits are made of a metal material; each of the electrical conductors of the plurality of electrical conductors includes a first electrical conductor and a second electrical conductor that are electrically coupled to each other; and the first electrical conductor is electrically coupled to the second electrical conductor by crimping or welding.

[0014] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.DRAWINGS

[0015] In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:

[0016] FIG. 1 is a perspective view of a heat exchanger including a standoff assembly and a heated section in accordance with teachings of the present disclosure;

[0017] FIG. 2 is a side cross-sectional view of a portion of the heat exchanger of FIG. 1 ;

[0018] FIG. 3 is a perspective view of a portion of the heat exchanger ofFIG. 1 ;

[0019] FIG. 4 is a side cross-sectional view of the standoff assembly of the heat exchanger of FIG. 1 in accordance with the teachings of the present disclosure;

[0020] FIG. 5 is another side cross-sectional view of the heat exchanger of FIG. 1 ;

[0021] FIG. 6 is a perspective view of a pressure retaining flange of the heat exchanger of FIG. 1 ;

[0022] FIG. 7 is a side view of a portion of the heat exchanger of FIG. 1 showing a power fitting subassembly electrically coupled to a heating element subassembly;

[0023] FIG. 8 is a side cross-sectional view of a portion of the heat exchanger including a resistive heating element of a resistive heater electrically coupled to an electrical conductor;

[0024] FIG. 9 is a side cross-sectional view of a push-in retention coupling feature to connect two electrical conductors of the heat exchanger according to principles of the present disclosure;

[0025] FIG. 10 is a perspective view of another resistive heater that may be incorporated into the heat exchanger of FIG. 1 instead of, or in addition to, the resistive heater illustrated above;

[0026] FIG. 11 is an enlarged perspective view of a portion of the resistive heater of FIG. 10; and

[0027] FIG. 12 is a perspective view of a support of the resistive heater of FIG. 10.

[0028] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.DETAILED DESCRIPTION

[0029] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0030] Referring to FIGS. 1-3, a heat exchanger according to the teachings of the present disclosure is illustrated and indicated by reference numeral 10. The heat exchanger 10 includes a heated section 14, a pressure retaining flange 16, a standoff assembly or non-heated section 18, and an electrical enclosure 20. The heated section 14 is disposed on one side of the pressure retaining flange 16 and includes a plurality of resistive heaters 22 extending parallel to a longitudinal axis 24 (FIG. 2) of the heat exchanger 10.

[0031] As shown in FIG. 2, each resistive heater 22 comprises at least one resistive heating element 26, a heating element conduit 30, and an optional central core 34. The heating element conduit 30 houses the heating element 26 extending therethrough and is made of a thermally and electrically insulating material such as a ceramic material, for example. The heating element conduit 30 includes a first port or in let / outlet 28a and a second port or in let / outlet 28b. The plurality of resistive heaters 22 are disposed within a tube or fluid vessel (not shown). Fluid can be pumped into the tube where it flows through one of the inlets / outlets 28a, 28b of the heating element conduits 30 until it exits via the other inlet / outlet 28a, 28b of the heating element conduits 30. It should be understood that the term "fluid" is to be construed to include solids, liquids, gases, and plasma, among other material states while remaining within the scope of the present disclosure. The central core 34 may extend through the heating element conduit 30 and may be coupled to the resistive heating element 26 at multiple locations along its length. In this way, the central core 34 positions the resistive heating element 26 within the heating element conduit 30 and acts as a support for the resistive heating element 26 within the heating element conduit 30. The resistive heaters 22 may be an open coil heater design (such as the resistive heating elements 26 as shown), or any heater construction that exposes the heating element surface area directly to a fluid flow (e.g., layered heater). In this way, fluid flowing through the heat exchanger 10 may be heated to high temperatures (i.e., up to 750 degrees Celsius or higher). Baffles 50 may also optionally be disposed within the tube and may act as support members that support the plurality of resistive heaters 22 relative to each other and relative to the tube.

[0032] With reference to FIGS. 1-3 and 6, the pressure retaining flange 16 is annular-shaped and extends transversely to the longitudinal axis 24 of the heat exchanger 10. As shown best in FIG. 6, the pressure retaining flange 16 includes a plurality of first apertures 52 and a plurality of second apertures 54. The plurality offirst apertures 52 are located near a periphery of the pressure retaining flange 16. The plurality of first apertures 52 are also circumferentially spaced apart around the pressure retaining flange 16 and surround the plurality of second apertures 54. Each first aperture 52 extends through the pressure retaining flange 16 (i.e., each first aperture 52 extends from a first axial end surface 58a of the pressure retaining flange 16 to an opposing second axial end surface 58b of the pressure retaining flange 16). Mechanical fasteners (not shown; screws, bolts, rivets, etc.) extend through the first apertures 52 and apertures (not shown) of a flange (not shown) of the tube, thereby securing the tube and the pressure retaining flange 16 to each other.

[0033] The plurality of second apertures 54 are located at or near a central portion of the pressure retaining flange 16. Each second aperture 54 extends through the pressure retaining flange 16 (FIG. 6; each second aperture 54 extends from the first axial end surface 58a of the pressure retaining flange 16 to the opposing second axial end surface 58b of the pressure retaining flange 16). Standoff conduits 56 of the standoff assembly 18 extend through respective second apertures 54 of the pressure retaining flange 16 and are secured (e.g., welded) to the pressure retaining flange 16.

[0034] The standoff assembly 18 is positioned on the other side, or the dry side, of the pressure retaining flange 16 (i.e., between the pressure retaining flange 16 and the electrical enclosure 20). With reference to FIG. 4, the standoff assembly 18 includes an annular-shaped enclosure adapter plate 62, the plurality of standoff conduits 56, and a plurality of electrical conductors 64. In some configurations, the entire standoff assembly 18 or one or more components of the standoff assembly 18 may be housed within a vessel (not shown).

[0035] The enclosure adapter plate 62 is welded to the electrical enclosure 20 and extends transversely to the longitudinal axis 24 (FIG. 2) of the heat exchanger 10. In some configurations, the enclosure adapter plate 62 is coupled to the electrical enclosure 20 by soldering, brazing, or mechanical fasteners, thereby forming a seal between the enclosure adapter plate 62 and the electrical enclosure 20. The enclosure adapter plate 62 is also spaced apart from the pressure retaining flange 16 to define a dry volume 72 therebetween (i.e., fluid flowing through the tube is inhibited from flowing to the dry volume 72). The enclosure adapter plate 62 has an outer diameter that is independent of the outer diameter of the pressure retaining flange 16. For example, the outer diameter of the enclosure adapter plate 62 may begreater than the outer diameter of the pressure retaining flange 16. Although the enclosure adapter plate 62 shown in the figures is flat, the enclosure adapter plate 62 could also take on other shapes that are not flat (e.g., the enclosure adapter plate 62 may be arcuate). In the example illustrated, the enclosure adapter plate 62 has a thickness that is smaller than a thickness of the pressure retaining flange 16.

[0036] As shown best in FIGS. 2 and 5, each of the standoff conduits 56 is aligned concentrically with a respective resistive heating element 26 and has a diameter that is smaller than a diameter of the heating element conduit 30. Each standoff conduit 56 includes a first end 76a secured to the pressure retaining flange 16 and a second end 76b secured to the enclosure adapter plate 62. In one form, the first end 76a of the standoff conduit 56 is welded to the pressure retaining flange 16 at the first axial end surface 58a or the second axial end surface 58b such that fluid flowing through the tube does not flow to the non-heated section 18 of the heat exchanger 10. The first end 76a and the second end 76b are secured and sealed to the pressure retaining flange 16 and enclosure adapter plate 62, respectively, via welding, brazing, or swaging, among others.

[0037] As shown in FIG. 2, the second end 76b of the standoff conduit 56 is fluidly sealed such that fluid within the heated section 14 is inhibited from escaping through the second end 76b of the standoff conduit 56. The second end 76b of the standoff conduit 56 may be fluidly sealed by a sealing structure 60 disposed at an axial end of the standoff conduit 56. The sealing structure 60 may include one or more of couplings, fittings and / or caps, for example, secured to each other via welding, brazing, swaging, and / or threads. In the example illustrated, the sealing structure 60 is disposed within the electrical enclosure 20. In some forms, the sealing structure 60 may be disposed external to (i.e., outside) the electrical enclosure 20.

[0038] The plurality of electrical conductors 64 extend through a respective standoff conduit 56 and is electrically coupled to a power supply (not shown) at first end and electrically coupled to a respective resistive heating element 26 at a second end. In the example illustrated, the second end of each electrical conductor 64 is electrically coupled to an end of the respective resistive heating element 26 at a location within the heating element conduit 30. In some forms, the second end of the electrical conductor 64 may be electrically coupled to an end of the respective resistive heating element 26 at a location outside of the heating element conduit 30. The first end of the electrical conductor 64 can be electrically coupled tothe power supply via mechanical fasteners, crimping, soldering, brazing, a push-in retention coupling feature, an electrically isolating compression fitting feature, or welding, for example. Similarly, the second end of the electrical conductor can be electrically coupled to the respective heating element 26 via mechanical fasteners, soldering, brazing, crimping or welding, for example.

[0039] In the example illustrated, each electrical conductor 64 includes a plurality of electrical conductors, which facilitates disassembly of the heat exchanger 10 for maintenance. In one form, with reference to FIGS. 2 and 7, each electrical conductor 64 includes a first electrical conductor 64a and a second electrical conductor 64b. The first electrical conductor 64a has a first end (not shown) electrically coupled to the power supply (not shown) and a second end 84 (FIG. 7) electrically coupled to the second electrical conductor 64b by crimping, mechanical fasteners, or any other suitable means that allows detachment from the second electrical conductor 64b.

[0040] With reference to FIG. 9, a push-in retention coupling feature 85 may facilitate electrical coupling of the first electrical conductor 64a and the second electrical conductor 64b. For example, the push-in retention coupling feature 85 may include a first end 85a and a second end 85b. The first end 85a defines an opening 89a that receives the second end 84 of the first electrical conductor 64a. The first end 85a of the coupling feature 85 may be secured (e.g., crimped) to the second end 84 of the first electrical conductor 64a received in the opening 89a. The second end 85b defines an opening 89b that includes an attachment feature 91 received therein and secured thereto. An end of the second electrical conductor 64b may be received in the opening 89b and extend at least partially through the attachment feature 91 such that an interference fit is created between the end of the second electrical conductor 64b and the attachment feature 91. In this way, the second electrical conductor 64b is electrically coupled to the first electrical conductor 64a. The second electrical conductor 64b may be conveniently removed by pulling the second electrical conductor 64b from the coupling feature 85 to disconnect it from the attachment feature 91 . In this way, the second electrical conductor 64b may be replaced from the heat exchanger 10 without the need for tools to disconnect it from the first electrical conductor 64a. In some forms, the coupling feature 85 may be located within the heated section of the heat exchanger 10.

[0041] In another form, a single electrical conductor extends without splicing from the heating element 26 through to the electrical enclosure 20 and is coupled through means of an electrically isolating compression fitting, thereby enabling easy field replacement of the element by end users. The first electrical conductor 64a extends through the standoff conductor 56, the pressure retaining flange 16 and into the heated section 14 of the heat exchanger 10. Insulation material 79 (FIG. 4) is disposed within each standoff conduit 56 and pressure retaining flange 16 and surrounds the first electrical conductor 64a extending through the standoff conduit 56 and the pressure retaining flange 16. The insulation material 79 can be ceramic preforms, for example. Insulation material 86 is disposed entirely within the heated section 14 and surrounds a respective first electrical conductor 64a located within the heated section 14. The insulation material 86 may be spaced apart from the insulation material 79 and can be ceramic preforms, for example.

[0042] With reference to FIGS. 7 and 8, the second electrical conductor 64b has a first end 88a (FIG. 7) electrically coupled to the second end 84 of the first electrical conductor 64a and a second end 88b (FIG. 8) electrically coupled to a termination end 87 of the respective resistive heating element 26 at a location within the heating element conduit 30. The second end 88b can be electrically coupled to the termination end 87 of the respective heating element 26 via mechanical fasteners, soldering, brazing, crimping or welding, for example. Each second electrical conductor 64b extends through a conductor conduit 90 disposed within the heated section 14. The conductor conduit 90 has a first end 92a and a second end 92b. In the example illustrated, the first end 92a (FIG. 7) is spaced apart from the insulation material 86 surrounding the first electrical conductor 64a and the second end 92b (FIG. 8) is spaced apart from the termination end 87 of the resistive heating element 26. Insulation material 94 is disposed within each conductor conduit 90 and surrounds the second electrical conductor 64b. The insulation material 94 can be ceramic preforms, for example. In some configurations, the electrical conductors 64a, 64b can be rods of various shapes and materials, or wires of various materials or forms (e.g., wires may be solid, stranded, bare, or with an insulation covering).

[0043] The standoff conduit 56, the first electrical conductor 64a, the sealing structure 60, and the insulating materials 79, 86 form a power fitting subassembly that is inserted into the heat exchanger 10 from a first end 25a of the heat exchanger 10. The first end 25a is located proximate electrical enclosure 20 andis inserted in the direction of the arrow shown in FIG. 4. The resistive heater 22, the second electrical conductor 64b, the conductor conduit 90 and the insulating material 94 form a heating element subassembly that is inserted into the heat exchanger 10 from a second end 25b of the heat exchanger 10 that is opposite the first end 25a (i.e., inserted in the direction of the arrow shown in FIG 5). In another form, a single electrical conductor extends without splicing from the heating element 26 through to the electrical enclosure 20 and is coupled through means of an electrically isolating compression fitting, thereby enabling easy field replacement of the heating element 26 by end users.

[0044] As shown in FIGS. 4 and 5, the heat exchanger 10 may optionally include at least one heat shield 96a, 96b (FIG. 5) and an insulation block 98. Each heat shield 96a, 96b inhibits heat transfer to the electrical enclosure 20. In the example illustrated, the heat shield 96a is disposed at or near the first end 92a of the conductor conduits 90 and is welded to the conductor conduits 90 (i.e., the conductor conduits 90 extend through the heat shield 96a). The heat shield 96b is disposed at or near the second end 92b of the conductor conduits 90 such the conductor conduits 90 extend through the heat shield 96b. Each heat shield 96a, 96b includes a sealing structure 99 surrounding a periphery thereof. The sealing structure 99 is engaged with the tube (not shown) of the heat exchanger 10, thereby further inhibiting heat transfer to the electrical enclosure 20. In the example illustrated, the heat shield 96b includes openings 80 (FIG. 3) located at or near a central area of the heat shield 96b. The openings 80 allow fluid flowing through the heat exchanger 10 to flow into or out of the heating element conduit 30. In some forms, the openings 80 of the heat shield 96b may be located at a periphery of the heat shield 96b or any other desired location that allows fluid flowing through the heat exchanger 10 to flow into or out of the heating element conduit 30.

[0045] The insulation block 98 is disposed at or near the second axial end surface 58b of the pressure retaining flange 16 and inhibits heat transfer to the electrical enclosure 20. The insulation block 98 surrounds the insulation material 86, which covers the first electrical conductor 64a. In the example illustrated, the insulation block 98 includes a plurality of stack pads coupled to the insulation material 86.

[0046] The heat exchanger 10 of the present disclosure provides the benefit of allowing the power fitting subassembly and the heating element subassembly to be conveniently decoupled from each other, which allows for repairsand replacement of individual resistive heaters 22, for example, without fully disassembling the entire heat exchanger 10. The heat exchanger 10 of the present disclosure also provides the benefit of allowing fluid flowing through the heat exchanger 10 to be heated to temperatures up to 1050 degrees Celsius or higher, for example, while removing the terminal connections from exposure to the vessel inlet and heated fluid, thereby enabling much higher inlet temperatures than prior art heaters where the termination is in the gas stream.

[0047] With reference to FIGS. 10-12, another resistive heater 122 according to the teachings of the present disclosure is illustrated. The resistive heater 122 may be incorporated into the heat exchanger 10 described above instead of, or in addition to, the resistive heater 22 as previously set forth. The structure and function of the resistive heater 122 may be similar or identical to the resistive heater 22 described above, apart from the exceptions described herein.

[0048] Each resistive heater 122 comprises at least one resistive heating element 126, a heating element conduit 130, a central core 134 (FIG. 11 ), and one or more supports 135 (only one support shown in the figures). The heating element conduit 130 houses the heating element 126 extending therethrough and is made of a thermally and electrically insulating material such as a ceramic material, for example. The heating element conduit 130 includes a first port or inlet / outlet 128a and a second port or inlet / outlet 128b. The central core 134 may extend through the heating element conduit 130 and may be coupled to the resistive heating element 126 at multiple locations along its length. In this way, the central core 134 positions the resistive heating element 126 within the heating element conduit 130 and acts as a support for the resistive heating element 126 within the heating element conduit 130. In the example illustrated, the central core 134 has an outer surface that is threaded or spiral, which supports multiple portions of the heating element 126 in respective grooves of the central core 134. In other forms, the central core 134 may have a smooth or unthreaded surface that supports or engages the heating element 126.

[0049] With reference to FIGS. 11 and 12, each support 135 is disposed within the heating element conduit 130 and is configured to support the weight of the heating element 126 and the central core 134. That is, in some forms, the heating element 126 may tend to sag or be displaced in certain operating conditions (e.g., thermal and / or mechanical loads). The support 135 supports the heating element 126 in such conditions to inhibit dropping of the heating element 126 within the heatingelement conduit 130. Each support 135 may be made of a high temperature material such as ceramic or metal material and is configured to engage an inner cylindrical surface of the heating element conduit 130. In the example illustrated, the support 135 has a triangular shape comprising apertures or openings 140 extending therethrough. The apertures 140 permit fluid to pass through the support 135 and reduce weight of the support 135. Fluid flowing through the conduit 130 may also flow along a periphery of the support 135. In some forms, the apertures 140 may permit electrical components (e.g., wires) to pass through the support 135. The support 135 engages the inner cylindrical surface of the conduit 130 at respective vertexes 135a of the support 135. In the example illustrated, each vertex 135a has a flat surface. In some forms, each vertex 135a may be arcuate or have another polygonal shape. In some forms, the support 135 may have a cylindrical shape, star shape, or any other suitable shape that is configured to support the heating element 126 and the central core 134 while allowing fluid flowing in the conduit 130 to pass through. In the example illustrated, one support 135 is located near or at the inlet / outlet 128b of the conduit 130. In other forms, additional supports may be located within the conduit 130 such as near or at the inlet / outlet 128a of the conduit 130 and / or between the inlet / outlets 128a, 128b of the conduit 130 (e.g., surrounding the central core 134 and / or engaging portions of the heating element 126).

[0050] With continued reference to FIG. 11 , an optional attachment member 138 mechanically couples the support 135 to the central core 134. That is, a first end of the attachment member 138 is coupled to the support 135 (e.g., welded to the support 135) and a second end of the attachment member 138 is coupled to the central core 134 (e.g., welded to the central core 134). In the example illustrated, the first end of the attachment member 138 is mechanically coupled to the support at a central portion of the support 135 and the second end of the attachment member 138 is mechanically coupled to the inner cylindrical surface of the central core 134 (i.e., within a cavity of the central core). In some forms, the first end of the attachment member 138 may be mechanically coupled to a face or edge of the support 135 and the second end of the attachment member 138 may be mechanically coupled to an outer surface of the central core 134. The attachment member 138 may be a rod, cable, wire, or any other suitable structure that facilities attachment of the support 135 to the central core 134 such that the weight of the central core 134 and the heating element 126 may be distributed to the support 135. In some forms, the attachmentmember 138 may be a pin that extends from the support 135 to the electrical enclosure 20 and may be provided with power from the electrical enclosure 20. In this way, the attachment member 138 may transfer power from the electrical enclosure 20 to the heating element 126 while inhibiting the transfer of power to the central core 134 and the support 135.

[0051] Unless otherwise expressly indicated herein, all numerical values indicating mechanical / thermal properties, compositional percentages, dimensions and / or tolerances, or other characteristics are to be understood as modified by the word “about” or "approximately" in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability.

[0052] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”

[0053] The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.

Claims

CLAIMSWhat is claimed is:

1. A heat exchanger comprising: a plurality of resistive heaters disposed at a first end of the heat exchanger, each resistive heater comprising: a heating element conduit comprising fluid flowing therethrough; and a resistive heating element disposed within the heating element conduit; a plurality of standoff conduits disposed at an opposing second end of the heat exchanger and configured to be coupled to an electrical enclosure, each of the standoff conduits having an axial end that is fluidly sealed; and a plurality of electrical conductors, each electrical conductor extending through a respective standoff conduit and having first and second ends, the first end electrically coupled to a power supply and the second end electrically coupled to a respective resistive heater.

2. The heat exchanger according to Claim 1 , wherein the plurality of heating element conduits are made of a ceramic material and the plurality of standoff conduits are made of a metal material.

3. The heat exchanger according to Claim 1 , wherein each of the electrical conductors of the plurality of electrical conductors comprises a first electrical conductor and a second electrical conductor that are electrically coupled to each other.

4. The heat exchanger according to Claim 3, wherein the second electrical conductor is electrically coupled to the respective resistive heater by crimping, welding, or a push-in retention coupling feature.

5. The heat exchanger according to Claim 3, wherein the first electrical conductor is electrically coupled to the second electrical conductor by crimping, welding, or a push-in retention coupling feature.

6. The heat exchanger according to Claim 3, further comprising a plurality of conductor conduits spaced apart from the plurality of standoff conduits, and wherein the first electrical conductor extends through a respective standoff conduit and the second electrical conductor extends through a respective conductor conduit.

7. The heat exchanger according to Claim 6, further comprising at least one heat shield secured to the plurality of conductor conduits.

8. The heat exchanger according to Claim 1 , further comprising a pressure retaining flange, and wherein a heated section is disposed on one side of the pressure retaining flange and a non-heated section is disposed on an opposite side of the pressure retaining flange.

9. The heat exchanger according to Claim 8, wherein each of the standoff conduits of the plurality of standoff conduits extends substantially through the pressure retaining flange and includes another end that is secured to the pressure retaining flange.

10. The heat exchanger according to Claim 1 , further comprising the electrical enclosure, and wherein the axial end of the standoff conduit is within the electrical enclosure.

11. A heat exchanger comprising: a plurality of resistive heaters disposed at a first end of the heat exchanger, each resistive heater comprising: a heating element conduit comprising fluid flowing therethrough; and a resistive heating element disposed within the heating element conduit; a plurality of standoff conduits disposed at an opposing second end of the heat exchanger and configured to be coupled to an electrical enclosure, each of the standoff conduits aligned concentrically with each of the resistive heating elements and having an end that is fluidly sealed; anda plurality of electrical conductors, each of the electrical conductors comprising a first electrical conductor and a second electrical conductor, the first electrical conductor extending through a respective standoff conduit and having first and second ends, the first end electrically coupled to a power supply, the second electrical conductor having third and fourth ends, the third end of the second electrical conductor electrically coupled to the second end of the first electrical conductor and the fourth end of the second electrical conductor electrically coupled to a respective resistive heater at a location within the heating element conduit.

12. The heat exchanger according to Claim 11 , wherein the plurality of heating element conduits are made of a ceramic material and the plurality of standoff conduits are made of a metal material.

13. The heat exchanger according to Claim 11 , the third end of the second electrical conductor is electrically coupled to the second end of the first electrical conductor by crimping, and wherein the fourth end of the second electrical conductor is electrically coupled to the respective resistive heater by crimping.

14. The heat exchanger according to Claim 11 , further comprising a plurality of conductor conduits spaced apart from the plurality of standoff conduits, and wherein the first electrical conductor extends through the respective standoff conduit and the second electrical conductor extends through the respective conductor conduit.

15. The heat exchanger according to Claim 14, further comprising at least one heat shield secured to the plurality of conductor conduits.

16. A heat exchanger comprising: a pressure retaining flange; a heated section disposed on one side of the pressure retaining flange, the heated section comprising: a plurality of resistive heaters, each resistive heater comprising: a heating element conduit comprising fluid flowing therethrough; anda resistive heating element disposed within the heating element conduit; and a non-heated section disposed on an opposite side of the pressure retaining flange, the non-heated section comprising: a plurality of standoff conduits having a first axial end and a second axial end, the first axial end of each of the standoff conduits is fluidly sealed, the second axial end of each of the standoff conduits is secured to the pressure retaining flange; and a plurality of electrical conductors extending through respective standoff conduits and having third and fourth ends, the third end electrically coupled to a power supply and the fourth end electrically coupled to a respective resistive heater.

17. The heat exchanger according to Claim 16, further comprising an electrical enclosure, and wherein the first axial end of the standoff conduit is within the electrical enclosure.

18. The heat exchanger according to Claim 16, wherein the plurality of heating element conduits are made of a ceramic material and the plurality of standoff conduits are made of a metal material.

19. The heat exchanger according to Claim 16, wherein each of the electrical conductors of the plurality of electrical conductors comprises a first electrical conductor and a second electrical conductor that are electrically coupled to each other.

20. The heat exchanger according to Claim 19, wherein the first electrical conductor is electrically coupled to the second electrical conductor by crimping or welding.21 . The heat exchanger according to Claim 1 , further comprising at least one support disposed within the heating element conduit.

22. The heat exchanger according to Claim 21 , wherein the at least one support includes one or more apertures.

23. The heat exchanger according to Claim 21 , further comprising a central core extending through the heating element conduit and supporting the resistive heating element, each support mechanically coupled to the central core.

24. The heating exchanger according to Claim 21 , wherein the at least one support is non-electrically conductive.

25. The heat exchanger according to Claim 11 , further comprising at least one support disposed within the heating element conduit.

26. The heat exchanger according to Claim 25, wherein the at least one support includes one or more apertures.

27. The heat exchanger according to Claim 25, further comprising a central core extending through the heating element conduit and supporting the resistive heating element, each support mechanically coupled to the central core.

28. The heating exchanger according to Claim 25, wherein the at least one support is non-electrically conductive.

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