METHODS AND SYSTEMS FOR A HEAT EXCHANGER

A heat exchanger may comprise a primary fluid path comprising an outer shell enclosing a primary cavity through which a primary fluid may flow; and a secondary fluid path coupled to the primary fluid path comprising a secondary fluid supply conduit, a secondary fluid exit conduit, and a first heat transfer element coupled fluidly between the secondary fluid supply conduit and the secondary fluid exit conduit, wherein the secondary fluid path is configured such that a secondary fluid may flow through the secondary fluid supply conduit, the first heat transfer element, and the secondary fluid exit conduit, which are in fluid communication with one another. The first heat transfer element, and additional heat transfer elements, may be disposed in the primary cavity such that the primary fluid contacts a secondary outer shell of the first heat transfer element.

FIELD

The present disclosure relates generally to the transfer of thermal energy through a heat exchanger.

BACKGROUND

There are many applications in which the transfer of thermal energy between two fluids (e.g., liquids and/or gases) would be desirable. For example, the cooling or heating of a certain fluid flow through a machine may cause more efficient or better operation of the machine. A heat exchanger may facilitate the desired exchange of thermal energy between fluids (e.g., a shell and tube heat exchanger or a plate and frame heat exchanger). The structure and design of the heat exchanger may affect the performance of the heat exchanger and the efficacy and efficiency of the transfer of thermal energy between fluids.

SUMMARY

In various embodiments, a heat exchanger may comprise a primary fluid path comprising an outer shell enclosing a primary cavity through which a primary fluid may flow; and a secondary fluid path coupled to the primary fluid path comprising a secondary fluid supply conduit, a secondary fluid exit conduit, and a first heat transfer element coupled fluidly between the secondary fluid supply conduit and the secondary fluid exit conduit, wherein the secondary fluid path is configured such that a secondary fluid may flow through the secondary fluid supply conduit, the first heat transfer element, and the secondary fluid exit conduit, which are in fluid communication with one another. The first heat transfer element may be disposed in the primary cavity such that the primary fluid contacts a secondary outer shell of the first heat transfer element.

The heat exchanger may be configured to allow calculation of a first heat exchange amount resulting from the primary fluid contacting the secondary outer shell of the first heat transfer element. A heat exchanger may comprise heat transfer elements, in addition to the first heat transfer element, coupled fluidly between the secondary fluid supply conduit and the secondary fluid exit conduit and disposed in the primary cavity. The additional heat transfer elements may be in series with each other and the first heat transfer element. Heat exchange amounts resulting from the primary fluid contacting the secondary outer shells of the additional heat transfer elements may be calculated. Therefore, the number of heat transfer elements with which the primary fluid may contact to achieve a certain amount of thermal energy transfer, or a certain primary fluid final temperature, may be determined and implemented (e.g., by adding or removing heat transfer elements, or causing the primary fluid to avoid contact with heat transfer elements in excess of the necessary number of heat transfer elements).

In various embodiments, heat exchange amounts achieved by the additional heat transfer elements may be adjusted by adjusting the flow rate of the secondary fluid into and through each of the heat transfer elements. A flow regulator may be coupled to the respective heat transfer element at a heat transfer element inlet, which may be adjusted to adjust the secondary fluid flow rate in and through the respective heat transfer element.

In various embodiments, a method may comprise fluidly coupling a first heat transfer element between a secondary fluid supply conduit and a secondary fluid exit conduit of a secondary fluid path of a heat exchanger, wherein the secondary fluid path comprises the secondary fluid supply conduit, the secondary fluid exit conduit, and the first heat transfer element, wherein the secondary fluid supply conduit, the secondary fluid exit conduit, and the first heat transfer element are in fluid communication with one another, such that the secondary fluid path is configured to allow a secondary fluid to flow therethrough; coupling the secondary fluid path to a primary fluid path, wherein the primary fluid path comprises a primary outer shell enclosing a primary cavity through which a primary fluid can flow, wherein the first heat transfer element is disposed in the primary cavity such that the primary fluid contacts the first heat transfer element; determining an initial temperature for the primary fluid, wherein the initial temperature is the temperature of the primary fluid before contacting the first heat transfer element; determining a desired output temperature for the primary fluid, wherein the desired output temperature is the temperature at which the primary fluid exits the primary fluid path; calculating a first heat exchange amount resulting from the primary fluid contacting the first heat transfer element; determining an additional number of heat transfer elements needed to contact the primary fluid to achieve the desired output temperature; coupling the additional number of heat transfer elements between the secondary fluid supply conduit and the secondary fluid exit conduit such that the secondary fluid path comprises the additional number of heat transfer elements; and/or disposing the additional number of heat transfer elements in the primary cavity. In various embodiments, the first heat transfer element and the additional heat transfer elements are in series in the primary cavity. In various embodiments, at least a portion of the primary fluid path is linear. In various embodiments, at least one of the secondary fluid supply conduit and the secondary fluid exit conduit is external to the primary cavity. In various embodiments, at least one of the secondary fluid supply conduit and the secondary fluid exit conduit is internal to the primary cavity.

In various embodiments, the method may further comprise flowing the primary fluid through the primary fluid path; and flowing the secondary fluid through the secondary fluid path. In various embodiments, the method may further comprise adjusting a first heat transfer element flow rate, which is a secondary fluid flow rate through the first heat transfer element; and calculating a first adjusted heat exchange amount resulting from the primary fluid contacting the first heat transfer element resulting from the adjustment of the secondary fluid flow rate. In various embodiments, the method may further comprise adjusting a second heat transfer element flow rate, which is a secondary fluid flow rate through a second heat transfer element of the additional heat transfer elements, in response to the adjusting the first heat transfer element flow rate and the calculating a first adjusted heat exchange amount.

In various embodiments, a method may comprise flowing a primary fluid through a primary fluid path of a heat exchanger in a first direction, wherein heat exchanger further comprises a secondary fluid path comprising a secondary fluid supply conduit, a secondary fluid exit conduit, and a plurality of heat transfer elements, wherein each heat transfer element of the plurality of heat transfer elements is fluidly coupled between the secondary fluid supply conduit and the secondary fluid exit conduit such that a secondary fluid flows into the heat exchanger through the secondary fluid supply conduit, through a respective heat transfer element of the plurality of heat transfer elements, and exits the respective heat transfer element through the secondary fluid exit conduit; calculating a heat exchange amount between the primary fluid and the secondary fluid caused by each of the plurality of heat transfer elements; determining an appropriate number of heat transfer elements of the plurality of heat transfer elements to achieve a desired thermal energy transfer amount between the primary fluid and the secondary fluid; and/or flowing the secondary fluid through the secondary fluid path, including the appropriate number of heat transfer elements, of the heat exchanger in a second direction. In various embodiments, the first direction and the second direction may be the same or different.

DETAILED DESCRIPTION

All ranges and ratio limits disclosed herein may be combined. It is to be understood that unless specifically stated otherwise, references to “a,” “an,” and/or “the” may include one or more than one and that reference to an item in the singular may also include the item in the plural.

Heat exchangers may comprise various designs (e.g., shell and tube or plate and frame) and/or various structures. For example,FIG.1illustrates a cross-sectional view of an exemplary shell and tube heat exchanger100. Heat exchanger100may comprise a primary fluid conduit110comprising a primary outer shell112enclosing a primary cavity114, through which a primary fluid (e.g., a liquid and/or gas) may flow. For example, primary fluid conduit110may serve as a primary fluid path for a primary fluid. Primary fluid conduit110may comprise an primary conduit inlet116, through which primary fluid102enters primary outer shell112and primary cavity114, and a primary conduit outlet118, through which primary fluid102exits primary outer shell112and primary cavity114.

Heat exchanger100may further comprise a secondary fluid conduit120comprising a secondary outer shell122enclosing a secondary cavity124, through which a secondary fluid106(e.g., a liquid and/or gas) may flow. At least a portion of secondary fluid conduit120may be disposed within primary cavity114, such that secondary outer shell122comes in contact with primary fluid102. As used herein, “secondary outer shell” will refer to the contact area of the primary and secondary fluids in a heat exchanger, or the surface region of the secondary fluid conduit or the secondary fluid path separating the primary and secondary fluids in a heat exchanger. In various embodiments, secondary fluid conduit120is disposed within primary cavity114such that primary fluid102surrounds secondary fluid conduit120. Primary cavity114and secondary cavity124may be fluidly separate such that primary fluid102and secondary fluid106may not mix or come in physical contact with one another.

Realizing that terminology in the heat exchanger technological arena may vary depending on the orientation of one fluid flow relative to another, or the type of process (e.g., heating or condensing), as used herein, parts of a heat exchanger with the designation “primary” are the fluid conduit (and associated components) and fluid which at least partially encapsulate or surround the other fluid conduit. The “primary” fluid may be the fluid upon which heat transfer is desired (i.e., the fluid that is desired to reach a certain temperature, phase, or the like). Accordingly, as used herein, parts of a heat exchanger with the designation “secondary” are the fluid conduit (and associated components) and fluid which is at least partially encapsulated or surrounded by the other fluid conduit (i.e., the primary fluid conduit). The “secondary” fluid may be fluid which transfers heat to or from the primary fluid to achieve the desired result. However, the components and their functions described herein (or the terminology used to refer to the components and their functions) may be reversed or changed without going outside the scope of this disclosure. For example, primary and secondary fluid conduits may be in contact and/or thermal communication with one another in any suitable manner, including not being disposed with one encapsulated in the other.

Secondary outer shell122may be in thermal communication with primary fluid102and/or secondary fluid106. Accordingly, thermal energy may be transferred between primary fluid102and secondary fluid106through secondary outer shell122. Depending on the objective, primary fluid102may be cooled or heated by secondary fluid106, or vice versa. For example, if the objective is to heat primary fluid102(or cool secondary fluid106), primary fluid102may enter primary cavity114through primary conduit inlet116having a temperature lower than when primary fluid102exits primary cavity114through primary conduit outlet118. Likewise, secondary fluid106may enter secondary cavity124(or the portion of secondary fluid conduit120disposed within primary cavity114) having a temperature higher than when secondary fluid106exits secondary cavity124(or the portion of secondary fluid conduit120disposed within primary cavity114). In this example, primary fluid102absorbs thermal energy from secondary fluid106while primary fluid102and secondary fluid106are present within heat exchanger100. Conversely, for example, if the objective is to cool primary fluid102(or heat secondary fluid106), primary fluid102may enter primary cavity114through primary conduit inlet116having a temperature higher than when primary fluid102exits primary cavity114through primary conduit outlet118. Likewise, secondary fluid106may enter secondary cavity124(or the portion of secondary fluid conduit120disposed within primary cavity114) having a temperature lower than when secondary fluid106exits secondary cavity124(or the portion of secondary fluid conduit120disposed within primary cavity114). In this example, primary fluid102transfers thermal energy to secondary fluid106, which secondary fluid106absorbs, while primary fluid102and secondary fluid106are present within heat exchanger100.

The flow directions of primary fluid102and secondary fluid106may be parallel (i.e., flowing in the same, or same general, direction), opposite (i.e., flowing in opposite, or generally opposite, directions), or any other directions which may optimize, or accomplish a desired, thermal energy transfer between primary fluid102and secondary fluid106. Additionally, primary cavity114(or the fluid path of primary fluid102) and/or secondary cavity124(or the fluid path of secondary fluid106) may comprise any shape or arrangement such as a zigzag, u-shape, spiral, or the like to accomplish the desired thermal energy transfer between primary fluid102and secondary fluid106. A heat exchanger design may comprise, in various embodiments, multiple passages where the secondary fluid conduit is exposed to the primary fluid in the primary fluid conduit one, two, or more times in an effort to efficiently transfer thermal energy between fluids.

Traditional structures or designs of heat exchangers, such as heat exchanger100inFIG.1, may cause flow patterns and streamlines of the fluids that may not be conducive to an ideal or desired thermal energy transfer between fluids. For example, the design of a heat exchanger may not allow precise calculation and prediction of the amount of heat transfer between a primary and secondary fluid, therefore precluding the precision in fluid temperatures which may be desired or required for a certain industrial application.

With reference toFIG.2, at least a portion of a heat exchanger200comprising heat transfer elements250within a fluid path is depicted, in accordance with various embodiments. Heat exchanger200may comprise a primary fluid conduit210comprising a primary outer shell212enclosing a primary cavity214, through which a primary fluid202(e.g., a liquid and/or gas) may flow. For example, primary fluid conduit210may serve as a primary fluid path for primary fluid202. Primary fluid conduit210may comprise an primary conduit inlet, through which primary fluid202enters primary outer shell212and primary cavity214, and a primary conduit outlet, through which primary fluid202exits primary outer shell212and primary cavity214. The primary fluid path and/or primary cavity214may be any suitable shape or arrangement such as a zigzag, u-shape, spiral, or the like. In various embodiments, at least a portion of the primary fluid path and/or primary cavity214may be linear.

In various embodiments, primary outer shell212may comprise an opening in which a hatch216may be disposed. Hatch216may be disposed in the opening to seal and/or separate (i.e., fluidly isolate) primary cavity214from the surrounding environment external to primary outer shell212and/or primary cavity214such that primary fluid202may not exit primary cavity214through the opening. In various embodiments, hatch216may be removed and/or rotated (e.g., about hinges coupled to primary outer shell212and hatch216) such that the opening in primary outer shell212causes primary cavity214to be in fluid communication with the surrounding environment external to primary outer shell212and/or primary cavity214. The opening in primary outer shell212may allow access to primary cavity214and components disposed therein (e.g., heat transfer elements250, secondary fluid exit conduit225, and/or the like).

Heat exchanger200may further comprise a secondary fluid path comprising a secondary fluid supply conduit221, a secondary fluid exit conduit225, and at least one heat transfer element250. An outer wall may enclose a secondary cavity throughout the secondary fluid path such that secondary fluid supply conduit221, secondary fluid exit conduit225, and heat transfer element(s)250may be in fluid communication with one another. Thus, a secondary fluid206may flow through secondary fluid supply conduit221, secondary fluid exit conduit225, and heat transfer element(s)250.

In various embodiments, secondary fluid supply conduit221may be a pathway through which secondary fluid206travels to reach heat transfer element(s)250. Secondary fluid supply conduit221may be disposed such that secondary fluid supply conduit221does not contact primary fluid202. Therefore, secondary fluid supply conduit221may be disposed in heat exchanger200external to primary cavity214and/or primary fluid conduit210. The flow of secondary fluid206within secondary fluid supply conduit221may be parallel to the flow of primary fluid202(i.e., primary fluid202and secondary fluid206flow in the same direction) or counter to the flow of primary fluid202(i.e., primary fluid202and secondary fluid206flow in opposite or otherwise different directions).

Each heat transfer element250may comprise a heat transfer element inlet253fluidly coupling secondary fluid supply conduit221to the respective heat transfer element250. At least one heat transfer element inlet253provides a path for secondary fluid206to flow from secondary fluid supply conduit221to the respective heat transfer element250. In various embodiments, a flow regulator255may be coupled to at least one heat element inlet253. Flow regulator255may be a valve or other similar device capable of increasing or decreasing the flow of secondary fluid206through heat transfer element inlet253and into and through the respective heat transfer element250. Flow regulator255may be electronically, mechanically, and/or manually operated to regulate flow of secondary fluid206. In various embodiments, a temperature change device257(e.g., a thermocouple, heater, cooler, and/or the like) may be coupled to at least one heat element inlet253and/or on any other suitable portion of a heat transfer element250or the secondary fluid path. Temperature change device257may be configured to facilitate a change in temperature of secondary fluid206flowing through the respective heat transfer element250(or any other part of the secondary fluid path to which the temperature change device affects), such that the heat exchange amount for the respective heat transfer element may be changed based on a desired thermal energy transfer amount. Temperature change device257may increase or decrease in temperature, causing a temperature change of the coupled portion of heat transfer element250, or the respective portion of the secondary fluid path, and secondary fluid206within. In various embodiments, temperature change device257may gradually change temperature of the relevant portion of the secondary fluid path. In various embodiments, each temperature change device257may sequentially change the temperature of secondary fluid206, and therefore, sequentially change the heat exchange amount between heat transfer elements250.

In various embodiments, heat transfer element(s)250may be coupled (fluidly and/or physically) between secondary fluid supply conduit221and secondary fluid exit conduit225such that secondary fluid206flows through secondary fluid supply conduit221, enters and flows through heat transfer element(s)250, and exits heat transfer element(s)250and flows through secondary fluid exit conduit225. Heat transfer elements250may be fluidly coupled in parallel between secondary fluid supply conduit221and secondary fluid exit conduit225. At least a portion of heat transfer element(s)250may be disposed within primary cavity214, such that the secondary outer shell of heat transfer element(s)250comes in contact with primary fluid202.

In various embodiments, heat transfer element(s)250may have a cross-sectional shape that is complementary to a cross-sectional shape of primary cavity214(the cross sections being taken perpendicular to the axis of flow of primary fluid202, as depicted inFIG.2), such that the cross-sectional shape of heat transfer element(s)250occupies at least a portion of the cross-sectional area of primary cavity214. That way, at least a portion of (or a majority or all of) primary fluid202may contact a secondary outer shell252of a heat transfer element250no matter where the primary fluid202is disposed in and/or flowing through primary cavity214. For example, the cross section of primary cavity214may be circular, and the cross section of heat transfer element(s)250may be circular, with an outer diameter that is complementary to the cross-sectional dimensions of the circular primary cavity214. Secondary outer shell252may comprise any suitable material that allows thermal energy exchange between primary fluid202and secondary fluid206contacting secondary outer shell252.

Heat transfer element(s)250within heat exchanger200may comprise any suitable shape or design (e.g., having a circular cross-sectional shape, a teardrop shape, a conical or frusto-conical shape, a spiral shape, a helical shape, and/or the like). The design of heat transfer elements250may be configured to contact primary fluid202, while allowing the flow of primary fluid202through primary cavity214to continue. As discussed above, the cross-sectional shape (i.e., the shape of the outermost perimeter of heat transfer element(s)250) may be any suitable shape, such as complementary to the cross-sectional shape of primary cavity214. In various embodiments, heat transfer element(s)250may comprise a design comprising filaments. With further reference toFIG.3, for example, a heat transfer element (e.g., heat transfer element250) may comprise a spiral design, such as heat transfer element350A. A spiral design may comprise a single filament disposed in a spiral design, such that secondary fluid206may enter the spiral design on one filament end of heat transfer element305A, and exit the spiral design on another filament end (e.g., the only other end) of heat transfer element305A. As another example, a heat transfer element (e.g., heat transfer element250) may comprise a web design, such as heat transfer element350B. A web design may comprise a filament network such that secondary fluid206may flow systematically through heat transfer element350B. During heat exchanger operation comprising heat transfer elements (e.g., heat transfer elements350A and/or350B), primary fluid202may flow between the filaments to continue flowing through primary cavity214.

In various embodiments, heat transfer elements250may comprise a two-dimensional shape. In other words, heat transfer elements250may span and take up space only in a direction substantially perpendicular to the flow of primary fluid202through primary cavity214(i.e., within at least a portion of the cross-sectional area of primary cavity214, as discussed above), other than the width of the secondary cavity through which secondary fluid206may flow. In various embodiments, heat transfer elements250may comprise a three-dimensional shape. In other words, heat transfer elements250may span in a direction substantially perpendicular to the flow of primary fluid202through primary cavity214, as discussed above, as well spanning along primary cavity214(i.e., axially and/or substantially in the direction of the flow of primary fluid202). For example, the spiral design of heat transfer element350A, or the web design of heat transfer element350B, may take the three-dimensional shape of a cone, such as heat transfer elements450, depicted inFIG.4, having a spiral conical shape. In various embodiments, heat transfer elements250may comprise different shapes or designs within a heat exchanger.

Primary cavity214and the secondary cavity enclosed within secondary outer shell252may be fluidly separate such that primary fluid202and secondary fluid206may not mix or come in physical contact with one another.

In various embodiments, heat exchanger200may comprise two or more heat transfer elements250, such as heat transfer elements250A and250B, as depicted inFIG.2. Heat transfer elements250may be disposed within primary cavity214in series such that primary fluid202contacts heat transfer elements250A and250B sequentially while flowing through and within primary cavity214. A heat exchanger (e.g., heat exchanger200) may comprise any suitable or desired number of heat transfer elements250.

In various embodiments, secondary fluid exit conduit225may be a pathway through which secondary fluid206travels in response to exiting a heat transfer element(s)250. Secondary fluid206flowing in each of multiple heat transfer elements250may flow into secondary fluid exit conduit225in response to exiting the respective heat transfer element250. Secondary fluid exit conduit225may be disposed in heat exchanger200internal or external to primary cavity214and/or primary fluid conduit210. In various embodiments, secondary fluid exit conduit225may comprise any suitable material. For example, secondary fluid exit conduit225may comprise insulation material to reduce or prevent thermal energy transfer between secondary fluid206within secondary fluid exit conduit225and adjacent primary fluid202flowing through primary cavity214. The flow of secondary fluid206within secondary fluid exit conduit225may be parallel to the flow of primary fluid202(i.e., primary fluid202and secondary fluid206flow in the same direction) or counter to the flow of primary fluid202(i.e., primary fluid202and secondary fluid206flow in opposite or otherwise different directions).

The secondary fluid path may comprise heat element outlets254fluidly coupling secondary fluid exit conduit225to respective heat transfer elements250. That is, each heat transfer element250may comprise at least one heat element outlet254fluidly coupled to the respective heat transfer element250and secondary fluid exit conduit225, such that the at least one heat element outlet254provides a path for secondary fluid206to flow from a respective heat transfer element250to secondary fluid exit conduit225.

Secondary fluid exit conduit225may transport secondary fluid206out of heat exchanger200, and/or away from contact with primary fluid202. The secondary fluid206in secondary fluid exit conduit225may have already participated in the thermal energy transfer between primary fluid202and secondary fluid206while secondary fluid206was flowing through a heat transfer element(s)250. To summarize the flow path of secondary fluid206, secondary fluid206may begin by flowing in secondary fluid supply conduit221, and different portions of secondary fluid206may flow into and through different heat transfer elements250. That is, the same portion of secondary fluid206may not flow through multiple heat transfer elements250. The portions of secondary fluid206exit their respective heat transfer elements250, and flow into secondary fluid exit conduit225. Secondary fluid exit conduit225may be within primary cavity214(e.g., as depicted inFIG.2A), or, in various embodiments, the secondary fluid exit conduit may be disposed outside primary cavity214, such that the secondary fluid exit conduit is not in contact with the primary fluid.

With reference toFIG.4, a heat exchanger400having heat transfer elements450comprising a spiral conical shape comprised in a secondary fluid path is depicted, in accordance with various embodiments. Elements with the like element numbering throughout the figures are intended to be the same. In accordance with various embodiments, heat exchanger400may comprise heat transfer elements450comprising a spiral conical shape. Heat transfer elements450A and450B may be comprised of a filament disposed in a spiral conical shape within primary cavity214. Heat transfer elements450A and450B may comprise a secondary outer shell452enclosing a secondary cavity in heat transfer elements450A and450B through which secondary fluid206may flow.

During operation, primary fluid202may flow through primary cavity214, and secondary fluid206may flow through secondary fluid supply conduit221. A first portion of secondary fluid206may flow through the heat transfer element inlet453for heat transfer element450A, which is fluidly coupled to, or a part of, heat transfer element450A. The heat transfer element inlet453for heat transfer element450A may be disposed between secondary fluid supply conduit221and heat transfer element450A (i.e., downstream of secondary fluid supply conduit221and upstream of heat transfer element450A) such that secondary fluid may flow from secondary fluid supply conduit221, and into and through the heat transfer element inlet453for heat transfer element450A to reach heat transfer element450A. In response, the first portion of secondary fluid206may enter heat transfer element450A, and flow therethrough. Secondary outer shell452may be in thermal communication with primary fluid202and/or secondary fluid206. While the first portion of secondary fluid206is in heat transfer element450A and flowing therethrough, thermal energy may be transferred between the first portion of secondary fluid206and primary fluid202in contact and/or proximate to secondary outer shell452of heat transfer element450A.

Depending on the objective, primary fluid202may be cooled or heated by secondary fluid206, or vice versa. For example, if the objective is to heat primary fluid202(or cool secondary fluid206), primary fluid202may enter primary cavity214having a temperature lower than after primary fluid202contacts one or more heat transfer elements450and/or when primary fluid202exits primary cavity214. Likewise, the first portion of secondary fluid206, discussed above, may enter heat transfer element450A through the respective heat transfer element inlet453having a temperature higher than when the first portion of secondary fluid206exits heat transfer element450A through the respective heat transfer element outlet454. In this example, the primary fluid202contacting heat transfer element450A absorbs thermal energy from the first portion of secondary fluid206present in heat transfer element450A. Conversely, for example, if the objective is to cool primary fluid202(or heat secondary fluid206), primary fluid202may enter primary cavity214having a temperature higher than after primary fluid202contacts one or more heat transfer elements450and/or when primary fluid202exits primary cavity214. Likewise, the first portion of secondary fluid206, discussed above, may enter heat transfer element450A through the respective heat transfer element inlet453having a temperature lower than when the first portion of secondary fluid206exits heat transfer element450A through the respective heat transfer element outlet454. In this example, the primary fluid202contacting heat transfer element450A transfers thermal energy to the first portion of secondary fluid206present in heat transfer element450A.

Having multiple heat transfer elements450in series, as discussed above in relation to heat transfer elements250inFIG.2, may allow calculated heat transfer events to take place involving primary fluid202while flowing through primary cavity214. A heat transfer event may be the thermal energy transfer between primary fluid202contacting a heat transfer element450and the portion of secondary fluid206within the heat transfer element450during the heat transfer event.

In implementing calculated heat transfer events, during operation, secondary fluid206may flow through secondary fluid supply conduit221. A first portion of secondary fluid206may flow into heat transfer element450A (the first heat transfer element450in series), and a second portion of secondary fluid206may flow through heat transfer element450B. The first and second portions of secondary fluid206may exit secondary fluid supply conduit221through the respective heat transfer element inlet453for each heat transfer element450. In various embodiments, primary fluid202may flow through primary cavity214at the same time as portions of secondary fluid206are flowing through respective heat transfer elements450. Primary fluid202may contact the secondary outer shell452of heat transfer element450A while the first portion of secondary fluid206is within heat transfer element450A. In response, a heat transfer event may occur wherein thermal energy is transferred between (i.e., to or from) primary fluid202and (i.e., from or to) the first portion of secondary fluid206through outer shell452of heat transfer element450A. Therefore, a certain first amount of thermal energy may be transferred to or from the primary fluid202. Subsequently, primary fluid202(which just participated in a heat transfer event with the first portion of secondary fluid206in heat transfer element450A) may contact another heat transfer element450(e.g., heat transfer element450B). In response, another heat transfer event may occur wherein thermal energy is transferred between (i.e., to or from) primary fluid202and (i.e., from or to) the second portion of secondary fluid206through outer shell452of heat transfer element450B. Therefore, a certain second amount of thermal energy may be transferred to or from primary fluid202. The first and second portions of secondary fluid206involved in the described heat transfer events may exit their respective heat transfer elements450, and continue to flow through and/or out of heat exchanger400through secondary fluid exit conduit225. Reference to the first and second portions of secondary fluid206flowing through respective heat transfer elements450is to illustrate that the same portion of secondary fluid206may not flow through multiple heat transfer elements450. However, secondary fluid206from secondary fluid supply conduit221may continue to flow into and through heat transfer elements450to continue to transfer thermal energy with continued flow of primary fluid202. In various embodiments, the secondary fluid may enter each heat transfer element (e.g., heat transfer elements450A and450B) having the same initial temperature (e.g., the temperature in secondary fluid supply conduit221).

Primary fluid202may contact any number of desired heat transfer elements450to cause primary fluid202to achieve a desired level of thermal energy absorption or loss. As such, the temperature change to primary fluid202resulting from contact with each heat transfer element450may be calculated, for example, for a certain starting temperature, flow rate, etc. of primary fluid202, and certain starting temperature(s) and flow rate(s) of secondary fluid206within each heat transfer element450(the temperature and/or flow rate of secondary fluid206may be adjusted for each heat transfer element450). Accordingly, a heat exchanger (e.g., heat exchanger400) may be designed with a number of heat transfer elements450, each having a known (i.e., calculated) respective heat exchange amount (i.e., the amount of thermal energy transferred to or from primary fluid202contacting the respective heat transfer element450with secondary fluid206flowing therethrough), that would achieve a desired temperature change in primary fluid202resulting from contact with all of the heat transfer elements450. Or, in various embodiments, primary fluid202may be directed to exit heat exchanger400, or directed to avoid contact with further heat transfer elements450, after a desired amount of heat transfer to or from primary fluid202has been achieved resulting from primary fluid202contacting the number of heat transfer elements450required to achieve the desired heat transfer. Additionally, the heat transfer achieved by each specific heat transfer element450may be calculated and/or adjusted by adjusting the secondary fluid206flow rate through a heat transfer element450. In various embodiments, as discussed above, the flow rate of secondary fluid206through a heat transfer element450may be achieved by adjusting the flow regulator255coupled to the heat transfer element inlet453for the respective heat transfer element450.

Providing a schematic diagram of a heat exchanger having heat transfer elements, as discussed herein,FIG.2Bdepicts heat exchanger200B. Similar to heat exchanger200inFIG.2A, heat exchanger200B comprises a primary fluid conduit210B enclosed by a primary outer shell212B. Primary fluid202may flow through primary fluid path210B. Heat exchanger200B may further comprise a secondary fluid path comprising a secondary fluid supply conduit221B, a secondary fluid exit conduit225B, and a desired number heat transfer elements150(a schematic version of heat transfer elements205depicted inFIG.2A). Heat transfer elements150may take any suitable shape or form, as discussed herein. Secondary fluid206may flow through the secondary fluid path.

As discussed herein, based on a desired thermal energy transfer amount between primary fluid202and secondary fluid206, any desired number of heat transfer elements150may be comprised in the secondary fluid path and disposed within primary fluid path210B and/or in contact with primary fluid path214B (as indicated by the ellipsis in secondary fluid exit conduit225B and the series of heat transfer elements150). That is, with each heat transfer element150effecting a known (calculated) heat exchange amount between primary fluid202and secondary fluid206, heat exchanger200B may be provided with the appropriate number of heat transfer elements150to achieve the desired thermal energy transfer amount between primary fluid202and secondary fluid206(e.g., for primary fluid202and/or secondary fluid206to achieve a desired temperature).

In various embodiments, the original temperature of heat transfer elements before effecting thermal energy transfer with a primary fluid can be regulated by the temperature or flow rate of the secondary fluid, as discussed herein, or in any other suitable manner. For example, the secondary flow path may be configured to facilitate the flow of electricity. Electricity may be what causes the heat transfer elements to have a certain temperature to facilitate a certain level of thermal energy transfer with the primary fluid. Therefore, the electricity provided to each heat transfer element can be adjusted (e.g., by a regulator) to achieve a desired temperature of the respective heat transfer element and a desired level of thermal energy transfer with the primary fluid. In such embodiments, keeping with the terminology used herein, the secondary fluid may be electrical current flowing through the secondary flow path and/or heat transfer elements (rather than a liquid or gas).

In various embodiments, the primary fluid path and heat transfer elements disposed therein can be disposed in any suitable direction. For example, the heat transfer elements to be contacted by the primary fluid can be disposed horizontally relative to one another. As another example, the heat transfer elements to be contacted by the primary fluid can be disposed substantially vertically relative to one another (or at any suitable angle(s) between horizontal and vertical). With heat transfer elements in a substantially vertical arrangement, the heat exchanger may be configured to cause a phase change of the primary fluid. For example, the primary fluid can be a liquid that is heated causing a phase change to vapor, the vapor travels along (e.g., up) the primary fluid conduit and contacts the heat transfer elements. At a desired level in the primary fluid conduit or at a desired heat transfer element (facilitated by the selected temperatures of the respective heat transfer elements), the heat exchanger may be configured to condense the vapor primary fluid into a liquid (e.g., heat exchangers in accordance with various embodiments of this disclosure may be used as stills for distillation).

With combined reference toFIGS.4and5, method500illustrates a method for making and operating a heat exchanger400, in accordance with various embodiments. In various embodiments, a first heat transfer element450A may be coupled to secondary fluid supply conduit221and secondary fluid exit conduit225(step502). The first heat transfer element450A may be fluidly coupled to secondary fluid supply conduit221and secondary fluid exit conduit225such that secondary fluid206may flow therethrough. Secondary fluid supply conduit221, secondary fluid exit conduit225, and heat transfer element(s)450may be comprised in the secondary fluid path. At least a portion of the secondary fluid path may be coupled to a primary fluid path (step504) comprising primary fluid conduit210enclosing primary cavity214. The first heat transfer element450A, and any other heat transfer elements450comprised in heat exchanger400, may be disposed in primary cavity214. In various embodiments, secondary fluid supply conduit221may be internal or external to primary fluid conduit210and/or primary cavity214. In various embodiments, secondary fluid exit conduit225may be internal or external to primary fluid conduit210and/or primary cavity214.

A user of heat exchanger400may desire a certain amount of thermal energy to be transferred to or from primary fluid202. Therefore, the initial temperature of primary fluid202may be determined (step506) (i.e., the temperature at which primary fluid202enters primary cavity214before contacting any heat transfer elements450). The desired final temperature of primary fluid202may be determined (step508) (i.e., the desired temperature of primary fluid202after flowing through primary cavity214and participating in heat transfer events with heat transfer elements450). Additionally, a flow rate for primary fluid202through primary cavity214may be determined. In order to achieve the desired output temperature of primary fluid202, an initial temperature of secondary fluid206may be determined (step506) (i.e., the temperature of secondary fluid206flowing through secondary fluid supply conduit221and entering heat transfer elements450, before participating in a heat transfer event with primary fluid202through secondary outer shell452of a heat transfer element450). Additionally, a flow rate of secondary fluid206flowing through the first heat transfer element450A may be determined or set (e.g., by adjusting flow regulator255coupled to heat transfer element inlet453of the first heat transfer element450A). In response to determining initial temperatures determined for primary fluid202and secondary fluid206, the flow rate of primary fluid202through primary cavity214, and the flow rate of secondary fluid206through the first heat transfer element450A, the thermal energy transfer between primary fluid202and secondary fluid206achieved by the first heat transfer element450A may be calculated (step510).

Using the calculated thermal energy transfer achieved by preceding heat transfer element450A, the thermal energy transfer between primary fluid202and secondary fluid206achieved by any subsequent heat transfer element450may be calculated (e.g., the second heat transfer element450B). Therefore, the number of heat transfer elements450necessary to achieve the desired final temperature of primary fluid202may be determined. In response, the additional heat transfer elements450may be coupled to secondary fluid supply conduit221and secondary fluid exit conduit225(step512) and disposed within primary cavity214. For example, heat transfer elements450may be coupled (i.e., added) to or decoupled (i.e., removed) from secondary fluid supply conduit221and secondary fluid exit conduit225through the opening in primary outer shell212with hatch216open. That is, in various embodiments, hatch216and the opening in primary outer shell212may allow access to primary cavity214to facilitate addition or removal of heat transfer elements to a heat exchanger based on the desired heat transfer. In various embodiments, heat exchanger400may be altered such that primary cavity214ends after the necessary heat transfer elements450, such that primary fluid202will be directed out of primary cavity214or away from further heat transfer elements450after contacting the necessary heat transfer elements450.

To achieve different amounts of thermal energy transfers via different heat transfer elements, in various embodiments, the size and/or shape of a heat transfer element added or removed from a heat exchanger may have a certain size, shape, and/or design. For example, to have a greater effect on heat transfer, a heat transfer element added or removed may comprise a larger shape (e.g., occupying more surface area of the primary cavity such that more of the primary fluid contacts such a heat transfer element), a design creating more surface area of the respective heat transfer element such that more of the primary fluid contacts such heat transfer element surface area, a secondary fluid conduit having a greater area (to allow for secondary fluid flow), and/or the like. To achieve a lesser effect on heat transfer, a heat transfer element added or removed may comprise characteristics opposite of those described above. Accordingly, depending on the desired thermal energy transfer result, a heat exchanger may comprise heat transfer elements of different sizes, shapes, and/or designs to achieve such a desired result.

To carry out the transfer of thermal energy between primary fluid202and secondary fluid206, primary fluid202may flow through the primary fluid path (e.g., primary cavity214) (step514) and secondary fluid206may flow through the secondary fluid path (step516). Secondary fluid206may flow through secondary fluid supply conduit221, and different portions of secondary fluid206may flow into heat transfer elements450. That is, the same portion of secondary fluid206may not flow through multiple heat transfer elements450. The portions of secondary fluid206in the respective heat transfer elements450may exit heat transfer elements450and flow into and through secondary fluid exit conduit225. The portions of secondary fluid206within heat transfer elements450may thermally interact with primary fluid202contacting the respective heat transfer element450. Thermal energy may be exchanged between primary fluid202and secondary fluid206through secondary outer shell452, which may separate primary fluid202and secondary fluid206. Therefore, in response to the thermal energy exchange, after contacting a heat transfer element450, primary fluid202may be warmer or colder, and after flowing through a heat transfer element450, the respective portion of secondary fluid206may be colder or warmer.

In various embodiments, the thermal energy exchange achieved by a heat transfer element450may be changed by adjusting the flow rate of secondary fluid206therethrough. The flow rate through a heat transfer element450may be adjusted (step518) by adjusting the flow regulator255coupled to the heat transfer element inlet453. In various embodiments, the thermal energy exchange achieved by a heat transfer element450may be changed by adjusting the temperature of secondary fluid206as it enters a heat exchanger element, such as by adjusting the temperature of a temperature change device257coupled to a heat element inlet253. Such an adjustment may change only the temperature of the portion of secondary fluid206entering the respective heat element450coupled to the adjusted temperature change device257. Therefore, the thermal energy exchanged achieved by a heat transfer element450may be modulated to fit application needs.

The heat exchanger systems and methods described herein allow a user to incrementally add or remove thermal energy from a fluid by contacting the fluid with a series of heat transfer elements. The thermal energy exchange achieved by each heat transfer element may be calculated and/or adjusted, and therefore, thermal energy addition or removal from a fluid may be more calculated and precise than other heat exchanger systems.