Abstract:
The present invention provides a heat exchange element for particular use in a film heat exchanger, such as a distillation system. The heat exchange element includes a substrate having a first surface and an opposing second surface. The first surface acts as a condenser surface. The heat exchange element further includes a composition disposed on at least a portion of the second surface. The composition has an exposed hydrophilic surface so as to provide a hydrophilic evaporator surface due to the composition being hydrophilic in nature. In contrast, the condenser surface is typically hydrophobic in nature. The use of the hydrophilic composition eliminates the nucleation of vapor bubbles and prevents gas film (or gas blanket) formation on the evaporator surface. As a result, the thermal resistance through the heat exchange element is decreased and the efficiency of the heat exchange element is increased.

Description:
[0001]    This application claims the benefit of U.S. Provisional Application No. 60/226,067, filed Aug. 17, 2000, which is hereby incorporated by reference. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    This invention relates to a heat exchange element and more specifically, relates to a heat exchange element including a condenser surface having hydrophobic properties and an evaporator surface having hydrophilic properties.  
         BACKGROUND OF THE INVENTION  
         [0003]    Heat exchange elements are used in heat exchangers in a variety of settings to accomplish a number of operations. Generally, a heat exchanger is a device that transfers heat from one gas or fluid to another or to the environment. Heat exchange elements are commonly employed in a distillation apparatus for the evaporation of a liquid and for its subsequent condensation. In the distillation apparatus, the heat exchange element may be in the form of flat bag-like elements of a thin sheet material placed against each other or may have other suitable forms. See, for example, U.S. Pat. Nos. 5,340,443, 5,512,141, and 5,770,020, all of which are hereby incorporated by reference. One suitable use for a distillation apparatus is the production of fresh water from sea water.  
           [0004]    Conventional sea water distillation systems, especially vapor compression systems, include an evaporator-condenser type assembly in which the latent heat of condensing steam is exchanged to sea water. This latent heat in turn causes the sea water to boil into a vapor. For purpose of illustration, a conventional heat exchange element for use in an evaporator-condenser assembly is shown in FIG. 1 and is generally indicated at  10 . The heat exchange element  10  includes a thermal conductor  12  which is impermeable to both water and vapor. This thermal conductor  12  acts as a substrate for the element  10 . The thermal conductor  12  has a first surface  14  on one side thereof and a second surface  16  on an opposite side thereof. The first surface  14  serves as a condenser surface where vapor is condensed into liquid and the second surface  16  serves as an evaporator surface where liquid is evaporated. In conventional heat exchange elements  10 , both the condenser surface  14  and the evaporator surface  16  are hydrophobic surfaces.  
           [0005]    When the conventional heat exchange element  10  is used in a distillation system, the heat exchange element  10  is connected to both an evaporator chamber (not shown) and a condenser chamber (not shown). Typically, the heat exchange element  10  is disposed between these two chambers. During operation of the distillation system, water droplets, generally indicated at  18 , form on the condenser surface  16  as the vapor condenses thereon to form a liquid condensate. A salt water film, generally indicated at  20 , forms on the evaporator surface  16  as the sea water evaporates into a vapor.  
           [0006]    One of the disadvantages associated with conventional heat exchange elements, such as the heat exchange element  10 , is that the heat exchange element  10  is likely to have a number of heat transfer regions present thereon during the heat transfer operation. Some of these regions include but are not limited to the following: convective heat transfer to liquid region, subcooled boiling, saturated nucleate boiling, forced convective heat transfer through liquid film, liquid deficient region, and convective heat transfer to vapor. The flow patterns of the fluid also vary depending upon the heat transfer characteristics of the region in which the fluid is flowing. In the conventional heat exchange element  10 , these various types of heat transfer regions are distributed over the heat surface in a stochastic manners However, it will be understood that not all of these heat transfer regions may be present on the heat exchange element  10  at any one time. The stochastic distribution of the regions results in the formation of bubble sites and dry spots that behave in a statistical manner in terms of boiling frequency and bubble size. The result is that heat transfer at a macroscopic level is neither constant nor periodic.  
           [0007]    For example, vapor bubbles often nucleate on the evaporator surface  16  resulting in pool or “pot” boiling. The pot boiling or bubbly flow, which occurs in the saturated nucleate boiling region, has a lower total heat transfer than other regions. Because heat transfer rates are linked to efficiency rates, this lower heat transfer equates to lower efficiency of the overall system. In addition and as illustrated in FIG. 1, a layer of soft scales, generally indicated at  22 , such as calcium carbonate, frequently forms on the evaporator surface  16  because a suitable layer of liquid is not maintained on the evaporator surface  16 . The formation of this layer  22  further reduces the heat transfer effectiveness in these regions of the evaporator surface  16  and thus reduces the effectiveness of the system. In order to prevent such formations, the sea water in the evaporator (not shown) is generally recirculated in an attempt to make sure that a layer of liquid flows along the entire evaporator surface  16  to prevent drying out thereof; however, this requires a significant amount of energy. Furthermore, a gas film or gas blanket, generally indicated at  24 , may form on the evaporator surface  16  which increases the thermal resistance of the system. This further reduces the heat transfer efficiency of the heat exchange element.  
           [0008]    Therefore, there is a continuing need for heat exchange elements which have improved heat transfer efficiency and require little, if any, outside energy to prevent soft scale formation.  
         SUMMARY OF THE INVENTION  
         [0009]    The present invention provides a heat exchange element having a water and vapor impermeable substrate. The substrate has a first surface which is typically hydrophobic and an opposing second surface. A composition is disposed on the second surface such that the composition provides an exposed hydrophilic surface. In one embodiment, the composition substantially covers the second surface so that the second surface essentially comprises a hydrophilic surface. According to the present invention, the first surface serves as a condenser surface of the substrate and the hydrophilic surface and any portion of the second surface not covered by the composition serve as an evaporator surface. One exemplary and preferred use for the heat exchange element of the present invention is in a distillation system for purifying sea water (or brine) to form fresh desalinated water.  
           [0010]    Advantageously, the use of the hydrophilic composition to define the evaporator surface eliminates the nucleation of vapor bubbles on the evaporator surface and also prevents gas film (or gas blanket) formation on this same surface. As a result, the thermal resistance through the heat exchange element is decreased and the efficiency of the heat exchange element is increased. Furthermore, since the evaporator surface attracts water, little, if any, power is required to recirculate the sea water or brine over the evaporator surface. The need to recirculate the sea water to prevent soft scale formation on the evaporator surface is reduced or eliminated, thereby, further increasing efficiency.  
           [0011]    In another embodiment, a distillation system is disclosed in which the heat exchange element of the present invention is included therein. The distillation system has an evaporator chamber and a condenser chamber with the heat exchange element of the present invention being disposed therebetween. The evaporator surface of the heat exchange element is in communication with the evaporator chamber and the condenser surface is in communication with the condenser chamber.  
           [0012]    These and other features and advantages of the present invention will be readily apparent from the following detailed description of the invention taken in conjunction with the accompanying drawings, wherein like reference characters represent like elements. 
       
    
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0013]    Other objects, features, and advantages of the invention discussed in the above summary of the invention will be more clearly understood from the following detailed description of the preferred embodiments, which are illustrative only, when taken together with the accompanying drawings in which:  
         [0014]    [0014]FIG. 1 is a cross-sectional side elevational view of a conventional heat exchange element;  
         [0015]    [0015]FIG. 2 is a cross-sectional side elevational view of a heat exchange element according to the present invention;  
         [0016]    [0016]FIG. 3 is a perspective view of one exemplary heat exchange element; and  
         [0017]    [0017]FIG. 4 is a cross-sectional side elevational view of the heat exchange element of FIG. 2 in a distillation system. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0018]    Referring now to FIG. 2, a heat exchange element is provided according to the present invention and is generally indicated at  100 . Heat exchange element  100  includes a substrate  102  which may be formed of any number of conventional materials and may have any number of shapes depending upon the precise application. Although the substrate  102  may be flexible in nature, it is preferred that the substrate  102  be formed so that it is rigid. Suitable substrates  102  also comprise those substrates which are capable of being metallized. Exemplary materials for forming the substrate  102  include, but are not limited to, plastics, such as thermoplastics; metals, such as titanium; stainless steel; and copper-nickel alloys; and any combination thereof. Preferred thermoplastic materials include, but are not limited to, polypropylene and polyethylene. In addition, carbon loaded versions of these thermoplastics are also suitable in the practice of the present invention.  
         [0019]    The substrate  102  has a first surface  104  and an opposite second surface  106 . The first surface  104  is intended to act as a condenser surface for producing a condensate. According to the present invention, a composition, generally indicated at  108 , is disposed on at least a portion of the second surface  106 . The composition  108  is selected so as to impart hydrophilic properties to at least the portion of the second surface  106  where the composition  108  is disposed. An evaporator surface  109  is thus defined by both the hydrophilic composition  108  and the second surface  106 . In the case where the composition  108  entirely covers the second surface  106 , the evaporator surface  109  is defined by the composition  108 . In the case where the composition  108  covers only a portion of the second surface  106 , the evaporator surface  109  is defined by the composition  108  and that portion of the second surface  106  which does not have the composition  108  disposed thereon. In the illustrated embodiment, the composition  108  covers the entire second surface  106 . Thus, the entire evaporator surface  109  is a hydrophilic surface.  
         [0020]    In one embodiment, the composition  108  is directly applied and bonded to the second surface  106  by using conventional processing techniques, including depositing and bonding the composition  108  in a plasma environment or by chemical vapor deposition. See, for example, U.S. Pat. No. 5,763,063, which is hereby incorporated by reference. It will be appreciated that these processes are merely exemplary in nature and any number of other suitable processes may be used to deposit the composition  108  on the second surface  106 . Alternatively, a primer layer (not shown) may be disposed between the composition  108  and the second surface  106  in order to promote improved bonding therebetween. The primer layer is selected so that sufficient and effective bonding results between the primer layer and the second surface  106  and between the primer layer and the composition  108 .  
         [0021]    The composition  108  of the present invention is formed of a hydrophilic material which is designed to withstand the operating conditions of the element  100  and also provide the improved benefits of the present invention. Suitable hydrophilic materials include, but are not limited to, metal oxides, such as titanium oxides (e.g., TiO x ) and nickel oxides (e.g., NiO x ). Preferred metal oxides include, but are not limited to, higher order titanium oxides and nickel oxides. Metal oxides, and preferably higher order titanium and nickel oxides, are preferable since these materials maintain their hydrophilic properties in the presence of boiling sea water and in reduced pressure environments. Higher order metal oxides are oxides of the metal with higher oxygen content (i.e. more oxygen atoms than metal atoms per molecule) (e.g., HTiO 3    −  or TiO 3 .2H 2 O). Metal oxides are generally unaffected by anti-scaling and anti-foaming agents, which are commonly employed in sea water distillation systems. Other suitable hydrophilic materials include, but are not limited to, zeolites (including those at various silicon-aluminum ratios), aluminophosphates, polymer hydrogels (e.g. acrylate derivatives, such as Hypan® (available from Lipo Chemicals, Inc. of Patterson, N.J.) and diphenyl ethylene (DPE)). Generally, the hydrophilicity of the composition is sufficient to result in 80% of the surface area of the evaporator portion of the heat exchanger to be wetted with a thickness of several molecular levels of the liquid to be evaporated.  
         [0022]    According to one preferred embodiment, the composition is a titanium oxide or nickel oxide which is coated on the second surface  106 . Generally, the composition is coated on the second surface at a thickness of from about 0.01 to about 2 μm and preferably at a thickness of from about 0.1 to about 0.2 μm. According to another embodiment, the composition is coated on the second surface at a thickness of from about 0.05 to about 0.4 μm.  
         [0023]    During operation of the heat exchange element  100  in a suitable heat exchanger (not shown), water droplets  110  form on the first (condenser) surface  104  as the vapor condenses thereon to form the liquid condensate. In the particularly preferred application of the heat exchange element  100  in sea water evaporator-condenser systems, a salt water film  112  forms on the evaporator surface  109  as the sea water is heated and evaporates therefrom. However, unlike the conventional heat exchange element  10  of FIG. 1, few, if any, scales form on the evaporator surface  109 . Because the material required to form the scale deposit remains in suspension with the sea water, scales are not formed. In addition, the lack of dry spots inhibits amalgamation of scales. This results in greater heat transfer at the evaporator surface  109  and thus increases the overall efficiency of the system in which the heat exchange element  100  is used.  
         [0024]    Furthermore, another of the disadvantages associated with the conventional heat exchange element  10  (FIG. 1) is overcome by the design of the heat exchange element  100  of the present invention. More specifically, the gas film or blanket  24  (FIG. 1) which forms on the evaporator surface of the conventional heat exchange element  10  does not form on the evaporator surface  109  of the present invention. Because the gas film  24  is eliminated, greater heat transfer results at the evaporator surface  109  because the liquid to be evaporated may more easily come into contact with the evaporator surface  109 . This also results in an overall increase in the efficiency of the system.  
         [0025]    While not being bound to any particular theory, it is believed that the hydrophilic evaporator surface  109  offers benefits relative to conventional evaporator surfaces because the hydrophilic surface  109  attracts the liquid to be evaporated and maintains a suitable layer of liquid on the evaporator surface  109  during the evaporation process. During the evaporation process, a liquid film spreads over the evaporator surface  109 . Because the liquid (e.g., sea water) is attracted to hydrophilic evaporator surface  109 , the liquid spreads into a fairly uniform film over the entire heat transfer surface (evaporator surface  109 ). During the evaporation process, the liquid to be evaporated is continuously fed to the evaporator surface  109  at a predetermined pressure and temperature which is sufficient to maintain a desired evaporation rate over the area of the evaporator surface  109 . By using a hydrophilic material on the evaporator surface  109 , the heat transfer surface is not marked by a variety of heat transfer regions but rather the heat transfer can be better controlled. The heat transfer mechanism maintains “evaporation” as opposed to “boiling” on the evaporator surface  109 . In other words, the system is forced into the forced convective heat transfer through liquid film region as opposed to the saturated nucleate boiling region. Thus, the “boiling” action is prevented and the formation of the gas film or blanket is eliminated because the liquid uniformly exists on the evaporator surface  109  due to the hydrophilic attraction therebetween. The evaporator surface  109  does not dry out due to a uniform liquid layer being maintained thereon.  
         [0026]    In the present invention, the liquid used in the evaporator process is generally maintained in the two-phase forced convection region of heat transfer. The liquid is thus maintained below the point of critical heat flux (CHF), i.e., the point of complete evaporation of the liquid film. When a liquid reaches CHF, dry spots form on the evaporator surface  109  because there is a lack of liquid in contact with the evaporator surface  109  at these dry spot locations. This causes a reduction in heat transfer and reduces the overall efficiency of the system. Avoiding the CHF condition places a limit on the level of evaporation that may be achieved for a given area of the evaporator (not shown) and at a given heat flux. However, this limit places little, if any, burden on many systems of industrial size and typical flow rates found therein.  
         [0027]    It is desirable to maintain the liquid film in the two-phase forced convection region heat transfer region because in this region, the liquid flows along the evaporator surface  109  while evaporation takes place. Dry out conditions are avoided because the liquid is maintained below CHF and at the same time the liquid effectively evaporates at the desired rate so as to produce efficient heat transfer. By staying in this region, the rate of heat transfer is optimized and the need to recirculate liquid to prevent drying is eliminated. Also, by staying in this region, the formation of entrained bubbles is also eliminated. The hydrophilic nature of the surface produces the foundation of uniformly distributed water molecules which in turn forms a uniform film of water above that foundation. The thinner the layer, the less effective the heat transfer.  
         [0028]    The heat exchange element  100  according to the present invention may have any number of configurations and shapes so long as at least a portion of the evaporator surface  109  includes the hydrophilic composition  108 . For example, the heat exchange element  100  may have a flat sheet design, a bag design, or a plate design. One suitable design is set forth in International Publication No. WO 98/31529, which is herein incorporated by reference in its entirety. This application discloses bag-like elements which stretch during use to provide for bulging during the pressurization of the interior of the element and is generally illustrated in FIG. 3.  
         [0029]    [0029]FIG. 3 shows an individual heat exchange element  150  for use in a film heat exchanger (not shown). The heat exchange element  150  is formed of two oppositely positioned plastic heat exchange films  152  which attach to one another at the top and the bottom of the element  150  and on the side which is on the left in the Figure. The films  152  are additionally bonded to each other along mutually parallel oblique bonding lines  154 , which divide the interior of the element  150  into parallel ducts  156  extending from one side of the element to the other. The hot vapor to be condensed is introduced into the interior of the element  150  from its at least partly open side  158 , which is on the right of the Figure. The vapor flows in the direction of the arrows set forth in the Figure. The condensate formed from the vapor in the ducts  156  leaves via the outlet opening  160  in the lower left comer of the element  150 . The liquid to be evaporated is directed between the elements  150  and is evenly distributed over exterior surfaces  153  of the heat exchange films  152 . In accordance with the present invention, the exterior surfaces  153  of the heat exchange films  152  are thus provided with a layer of hydrophilic material resulting in the exterior surfaces  153  being hydrophilic. It will be appreciated that this illustrated embodiment is merely exemplary in nature and any number of heat exchange structures may be used in the practice of the present invention so long as a portion of the evaporator surface  109  is made hydrophilic.  
         [0030]    Now referring to FIG. 4 in which an exemplary distillation system employing the heat transfer element  100  of the present invention is illustrated and generally indicated at  200 . The distillation system  200  includes a condenser chamber  202  and an evaporator chamber  204  with the heat exchange element  100  being disposed therebetween. The condenser and evaporator chambers  202 ,  204 , respectively, are typically not in direct communication with each other. The hydrophilic evaporator surface  109  of the heat exchange element  100  faces the evaporator chamber  204  and is in communication therewith. Similarly, the condenser surface  104  faces the condenser chamber  202  and is in communication therewith. The distillation system  200  operates like other traditional distillation systems in that there is an evaporation process for evaporation of a liquid and a condensation process for the subsequent condensation of vapor to a liquid condensate. This system  200  finds particular utility in sea water distillation applications for producing purified water from the sea water.  
         [0031]    According to one preferred embodiment, the heat exchange element  100  is used in a vacuum vapor compression distillation process, both of the mechanical and thermal types. In thermal vapor recompression evaporators, the inertia of the steam is used for recycling part of the evaporators through ejectors. In mechanical vapor recompression evaporators, all of the vapor is recycled back as heating steam using vapor compression with high pressure fans or compressors.  
         [0032]    While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.