Heat exchanger

A u-tube heat exchanger, comprising:

• a cooling chamber with an inlet and an outlet;
• an inlet chamber with an inlet;
• an outlet chamber with an outlet, the inlet chamber arranged within the outlet chamber;
• a tube sheet with a plurality of circularly arranged tube sheet holes, the tube sheet separates the cooling chamber on a first side from the outlet chamber on the second side;
• said u-tube heat exchanger having a central, longitudinal axis, a plurality of heat exchange u-tubes circumferentially arranged around said central, longitudinal axis, each of said u-tubes having a feed end and a discharge end, each of said plurality of heat exchange u-tubes comprising, in sequence:
• a first tube extending from said feed end to a downstream end,
• a u-bend, and
• a second tube extending from said u-bend and terminating at said discharge end, each u-bend being entirely radially spaced from said central longitudinal axis of said heat exchanger, such that the first tube, the u-bend and the second tube of each u-tube are all radially offset on one common side of said central longitudinal axis,
• a tapered tubular wall section within said first tube which tapers towards and is closer to said u-bend than said feed end, wherein an inner diameter of said feed end and an inner diameter of an upstream end of said tapered tubular wall section are the same;
• a plurality of inlet tubes each having open inlet and discharge ends, each inlet tube respectively cooperating with one of said circularly arranged holes of the tube sheet and each discharge end extending into and terminating within said first tube upstream of said tapered tubular wall section, each of said plurality of inlet tubes including an outer surface layer of insulation, said outer surface layer of insulation being spaced from an inner wall surface of said first tube to define an annular flow channel, wherein said outer surface layer of insulation terminates prior to said discharge end of said inlet tube to provide a wider portion of said annular flow channel at said discharge end of said inlet tube, said discharge end cooperating with said tapered tubular wall to split and force a portion of synthesis gas emanating from said inlet tube into said wider portion of said annular flow channel, and flow in a direction opposite to said emanating synthesis gas, through said tube sheet into said outlet chamber, and a second portion of said synthesis gas that continues to flow towards the u-bend of the u-tube, through said second tube and through said tube sheet into said outlet chamber, such that synthesis gas flowing in said opposite direction through said annular flow channel and exiting said annular flow channel through said tube sheet and into said outlet chamber, and synthesis gas flowing forward through said second tube and exiting said discharge end through said tube sheet and into said outlet chamber, will be cooled by indirect heat transfer in said cooling chamber, such that the tube sheet will only come in direct contact with cooled synthesis gas passing through said annular flow channel of said inlet tube and cooled synthesis gas passing through said outlet chamber, and wherein the pressure drops and heat transfer coefficients of the synthesis gas flowing through the first and second tubes and exiting the u-tubes are equalized by reducing the diameter of the second tubes relative to the diameter of the feed end of the first tubes, such that cooled synthesis gas exiting the annular flow channel at the feed end of each of the first tubes of the plurality of u-tubes and passing through the tube sheet has a temperature equal to the cooled synthesis gas exiting the discharge end of the second tubes of the plurality of u-tubes and passing through the tube sheet, thereby avoiding a temperature gradient across the tube sheet;
• an inlet tube plate arranged so that it separates the inlet chamber from the outlet chamber, wherein the inlet tube plate has a plurality of circularly arranged inlet tube plate holes, each of which is connected to said open inlet end of each of said inlet tubes;
• said plurality of heat exchange u-tubes extend within the cooling medium chamber in contact with the cooling medium on a shell side of the u-tubes,
• wherein the only fluid connection between the inlet chamber and the tube sheet and the inside of the u-tubes is via a fluid passage of the inlet tubes, whereby both ends of the u-tubes as well as the tube sheet are in contact with only the cooled synthesis gas on the tube side of the u-tubes and the tube sheet, and
• wherein the insulation layer prevents heat transfer between synthesis gas flowing inside the inlet tubes and in the annular channel.