Heat exchanger system and method

Abstract

A heat exchanger includes a shell and a sheet assembly disposed within the shell. The sheet assembly may include a number of substantially parallel rectangular sheets configured such that they define first passageways extending generally in a first direction and second passageways extending generally in a second direction perpendicular to the first direction. The sheet assembly may be configured such that communicating a first fluid through the first passageways and communicating a second fluid through the second passageways causes heat transfer between the first and second fluids. For example, the first fluid may comprise high pressure vapor and the second fluid may comprise a liquid solution such that the communicating the high pressure vapor and the liquid solution through the first and second passageways, respectively, causes at least a portion of the high pressure vapor to condense and at least a portion of liquid solution to boil off.

1 . A heat exchanger apparatus, comprising: 
 a shell; and    a sheet assembly disposed within the shell, the sheet assembly comprising a plurality of sheets arranged such that the plurality of sheets define a plurality of passageways operable to communicate at least two fluids within the shell such that heat is transferred between the at least two fluids.    
   
   
       2 . The heat exchanger apparatus of  claim 1 , wherein: 
 the shell comprises a substantially cylindrical portion extending in a first direction;    each of the plurality of sheets extending in a second direction substantially perpendicular to the first direction; and    each of the plurality of passageways defined by a pair of adjacent and substantially parallel sheets.    
   
   
       3 . The heat exchanger apparatus of  claim 1 , wherein each of the plurality of sheets comprises a rectangular shape.  
   
   
       4 . The heat exchanger apparatus of  claim 1 , wherein: 
 each of the plurality of passageways is defined by a pair of adjacent and substantially parallel sheets; and    a first one of the pair of sheets comprises one or more protrusions operable to contact an adjacent second one of the pair of sheets in order to maintain the passageway between the first and second sheets.    
   
   
       5 . The heat exchanger apparatus of  claim 4 , wherein the one or more protrusions associated with the first sheet comprise one or more stiffening ribs.  
   
   
       6 . The heat exchanger apparatus of  claim 4 , wherein: 
 the first sheet comprises one or more first corrugations extending in a first direction;    the second sheet comprises one or more second corrugations extending in a second direction different from the first direction; and    wherein the one or more first corrugations in the first sheet are configured to contact the one or more second corrugations in the second sheet in order to maintain the passageway between the first and second sheets.    
   
   
       7 . The heat exchanger apparatus of  claim 1 , wherein: 
 the plurality of sheets are arranged substantially parallel to each other;    each of the plurality of passageways is defined by a pair of adjacent and substantially parallel sheets; and    the plurality of passageways comprise one or more first passageways extending generally in a first direction and one or more second passageways extending generally in a second direction perpendicular to the first direction.    
   
   
       8 . The heat exchanger apparatus of  claim 7 , wherein the plurality of passageways comprise the one or more first passageways alternating with the one or more second passageways.  
   
   
       9 . The heat exchanger apparatus of  claim 7 , wherein; 
 the one or more first passageways are configured to communicate a first fluid;    the one or more second passageways are configured to communicate a second fluid; and    wherein the one or more first passageways are disposed in relation to the one or more second passageways such that communication of the first fluid and second fluids through the first and second passageways, respectively, causes heat transfer between the first and second fluids.    
   
   
       10 . The heat exchanger apparatus of  claim 9 , wherein; 
 the first fluid comprises vapor; and    the second fluid is selected from the group consisting of saltwater, seawater, fermentation broth, and brine.    
   
   
       11 . The heat exchanger apparatus of  claim 10 , wherein the vapor comprises steam.  
   
   
       12 . The heat exchanger apparatus of  claim 9 , wherein the one or more first passageways are separated from the one or more second passageways such that the first fluid is kept separate from the second fluid.  
   
   
       13 . The heat exchanger apparatus of  claim 9 , further comprising one or more gaskets disposed in contact with each of the plurality of sheets, the one or more gaskets operable to substantially prevent the first fluid from contacting the second fluid.  
   
   
       14 . The heat exchanger apparatus of  claim 1 , wherein: 
 each of the plurality of sheets comprises a rectangular shape having four edges;    the plurality of sheets are arranged substantially parallel to each other such that a first one of the plurality of sheets is located between a second one of the plurality of sheets and a third one of the plurality of sheets;    the first sheet is coupled to the second sheet at both a first and second edge of the first sheet, the first and second edges of the first sheet being opposite each other and generally parallel; and    the first sheet is coupled to the third sheet at both a third and fourth edge of the first sheet, the third and fourth edges of the first sheet being opposite each other and generally parallel.    
   
   
       15 . The heat exchanger apparatus of  claim 14 , wherein: 
 the first sheet comprises a first flange at the first edge of the first sheet, a second flange at the second edge of the first sheet, a third flange at the third edge of the first sheet, and a fourth flange at the fourth edge of the first sheet;    the second sheet comprises a first flange at a first edge of the second sheet and a second flange at a second edge of the second sheet, the first and second flanges of the second sheet being coupled to the first and second flanges, respectively, of the first sheet; and    the third sheet comprises a first flange at a first edge of the third sheet and a second flange at a second edge of the third sheet, the first and second flanges of the third sheet being coupled to the third and fourth flanges, respectively, of the first sheet.    
   
   
       16 . The heat exchanger apparatus of  claim 14 , wherein the first sheet is coupled to the second sheet at both the first and second edges of the first sheet by at least one weld, brazed joint, crimp clamp, crimped joint or fastener.  
   
   
       17 . The heat exchanger apparatus of  claim 1 , further comprising one or more wheels coupled to the sheet assembly and operable to position the sheet assembly within the shell.  
   
   
       18 . The heat exchanger apparatus of  claim 1 , further comprising: 
 a plurality of mounting devices coupled to the shell and operable to mount the sheet assembly, each of the plurality of mounting devices associated with a respective corner of the sheet assembly; and    one or more gaskets, each gasket disposed between one of the mounting devices and the respective corner of the sheet assembly and operable to substantially seal the plurality of passageways at the respective corner of the sheet assembly.    
   
   
       19 . The heat exchanger apparatus of  claim 1 , wherein the shell comprises: 
 a first inlet operable to communicate vapor into the shell; and    a first outlet operable to communicate vapor condensate formed from the vapor out of the shell.    
   
   
       20 . The heat exchanger apparatus of  claim 19 , wherein the shell further comprises: 
 a second inlet operable to communicate a solution into the shell; and    a second outlet operable to communicate at least a portion of the solution out of the shell.    
   
   
       21 . The heat exchanger apparatus of  claim 20 , further comprising a pump operable to pump at least a portion of the solution communicated out of the shell through the second outlet back into the shell through the second inlet.  
   
   
       22 . The heat exchanger apparatus of  claim 20 , wherein the shell further comprises a third outlet operable to allow vapor generated from the solution boiling within the shell to escape the shell.  
   
   
       23 . The heat exchanger apparatus of  claim 1 , wherein at least one of the plurality of sheets is formed from sheet metal.  
   
   
       24 . The heat exchanger apparatus of  claim 1 , wherein at least one of the plurality of sheets is formed from one or more polymer materials.  
   
   
       25 . The heat exchanger apparatus of  claim 1 , wherein at least one of the plurality of sheets is formed from a polymer selected from the group consisting of high-density polyethylene (HDPE), low-density polyethylene (LDPE), and polypropylene.  
   
   
       26 . The heat exchanger apparatus of  claim 1 , wherein at least one of the plurality of sheets is formed from a polymer selected from the group consisting of high-impact polystyrene (HIPS), ultra-high MW polyethylene, polyvinyl chloride (PVC), and acrylic.  
   
   
       27 . The heat exchanger apparatus of  claim 1 , wherein at least one of the plurality of sheets is formed from high-density polyethylene (HDPE) that has been drawn through a die to align the HDPE molecules in a direction perpendicular to a surface of the sheet in order to increase the thermal conductivity of the sheet.  
   
   
       28 . A method of providing heat exchange, comprising: 
 communicating a first fluid through a heat exchanger comprising a shell and a sheet assembly disposed within the shell, the sheet assembly comprising a plurality of sheets arranged such that the plurality of sheets define one or more first passageways and one or more second passageways, wherein communicating the first fluid through the heat exchanger comprises communicating the first fluid through the one or more first passageways defined by the sheet assembly;    communicating a second fluid through the heat exchanger, wherein communicating the second fluid through the heat exchanger comprises communicating the second fluid through the one or more second passageways defined by the sheet assembly; and    wherein communicating the first fluid through the one or more first passageways defined by the sheet assembly and communicating the second fluid through the one or more second passageways defined by the sheet assembly causes heat transfer between the first and second fluids.    
   
   
       29 . The method of  claim 28 , wherein the first fluid comprises vapor and the second fluid comprises a liquid.  
   
   
       30 . The method of  claim 28 , wherein: 
 the first fluid comprises vapor; and    communicating the vapor through the one or more first passageways defined by the sheet assembly comprises at least a portion of the vapor condensing within the one or more first passageways.    
   
   
       31 . The method of  claim 30 , wherein: 
 the second fluid comprises a liquid; and    communicating the liquid through the one or more second passageways defined by the sheet assembly comprises at least a portion of the liquid boiling and creating vapor.    
   
   
       32 . The method of  claim 31 , wherein the second fluid is selected from the group consisting of saltwater, seawater, fermentation broth, and brine.  
   
   
       33 . The method of  claim 28 , wherein: 
 communicating the first fluid through the heat exchanger comprises communicating the first fluid into the shell through one or more first inlets formed in the shell, through the one or more first passageways defined by the sheet assembly, and out of the shell through one or more first outlets formed in the shell; and    communicating the second fluid through the heat exchanger comprises communicating the second fluid into the shell through one or more second inlets formed in the shell, through the one or more second passageways defined by the sheet assembly, and out of the shell through one or more second outlets formed in the shell.    
   
   
       34 . The method of  claim 33 , wherein: 
 the first fluid comprises vapor;    communicating the vapor through the heat exchanger comprises at least a portion of the vapor condensing within the one or more first passageways defined by the sheet assembly;    the second fluid comprises a liquid; and    communicating the liquid through the heat exchanger comprises at least a portion of the liquid boiling within the one or more second passageways defined by the sheet assembly.    
   
   
       35 . The method of  claim 33 , wherein: 
 the second fluid comprises a liquid; and    communicating the second fluid through the heat exchanger comprises communicating the liquid into the shell through one or more first inlets formed in the shell, communicating the liquid through the one or more second passageways defined by the sheet assembly such that at least a portion of the liquid boils and forms vapor, allowing the vapor to escape the shell through one or more first outlets formed in the shell, and communicating at least a portion of the unboiled liquid out of the shell through one or more second outlets formed in the shell;    
   
   
       36 . The method of  claim 28 , wherein the heat exchanger is configured such that the first fluid communicated through the heat exchanger is prevented from mixing with the second fluid communicated through the heat exchanger.  
   
   
       37 . An apparatus for use in a heat exchanger, the apparatus being disposed within a shell and comprising: 
 a plurality of sheets arranged such that the plurality of sheets define a plurality of passageways operable to communicate at least two fluids within the shell such that heat is transferred between the at least two fluids.    
   
   
       38 . The apparatus of  claim 37 , wherein each of the plurality of sheets comprises a rectangular shape.  
   
   
       39 . The apparatus of  claim 37 , wherein: 
 each of the plurality of passageways is defined by a pair of adjacent and substantially parallel sheets; and    a first one of plurality of sheets comprises one or more protrusions operable to contact an adjacent second one of plurality of sheets in order to maintain the passageway between the first and second sheets.    
   
   
       40 . The apparatus of  claim 37 , wherein: 
 the plurality of sheets are arranged substantially parallel to each other;    each of the plurality of passageways is defined by a pair of adjacent and substantially parallel sheets; and    the plurality of passageways comprise one or more first passageways extending generally in a first direction and one or more second passageways extending generally in a second direction perpendicular to the first direction.    
   
   
       41 . The apparatus of  claim 40 , wherein the plurality of passageways comprise the one or more first passageways alternating with the one or more second passageways.  
   
   
       42 . The apparatus of  claim 40 , wherein; 
 the one or more first passageways are configured to communicate a first fluid; and    the one or more second passageways are configured to communicate a second fluid.    
   
   
       43 . The apparatus of  claim 1 , wherein: 
 each of the plurality of sheets comprises a rectangular shape having four edges;    the plurality of sheets are arranged substantially parallel to each other such that a first one of the plurality of sheets is located between a second one of the plurality of sheets and a third one of the plurality of sheets;    the first sheet is coupled to the second sheet at both a first and second edge of the first sheet, the first and second edges of the first sheet being opposite each other and generally parallel; and    the first sheet is coupled to the third sheet at both a third and fourth edge of the first sheet, the third and fourth edges of the first sheet being opposite each other and generally parallel.    
   
   
       44 . The heat exchanger apparatus of  claim 43 , wherein: 
 the first sheet comprises a first flange at the first edge of the first sheet, a second flange at the second edge of the first sheet, a third flange at the third edge of the first sheet, and a fourth flange at the fourth edge of the first sheet;    the second sheet comprises a first flange at a first edge of the second sheet and a second flange at a second edge of the second sheet, the first and second flanges of the second sheet being coupled to the first and second flanges, respectively, of the first sheet; and    the third sheet comprises a first flange at a first edge of the third sheet and a second flange at a second edge of the third sheet, the first and second flanges of the third sheet being coupled to the third and fourth flanges, respectively, of the first sheet.    
   
   
       45 . The apparatus of  claim 37 , wherein at least one of the plurality of sheets is formed from sheet metal.  
   
   
       46 . The apparatus of  claim 37 , wherein at least one of the plurality of sheets is formed from one or more polymer materials.  
   
   
       47 . The apparatus of  claim 37 , wherein at least one of the plurality of sheets is formed from high-density polyethylene (HDPE) that has been drawn through a die to align the HDPE molecules in a direction perpendicular to a surface of the sheet in order to increase the thermal conductivity of the sheet.