Counter-flow heat exchanger

A heat exchanger for exchanging heat between two fluid flows in counter-flow arrangement comprising:

• a core region having a first end, a second end and defining a length therebetween,
• a first set of heat exchanging passageways and a second set of heat exchanging passageways disposed at least partially therein the core region;
• a first fluid inlet plenum disposed adjacent the first end of the core region and a first fluid outlet plenum disposed adjacent the second end of the core region, the first fluid inlet plenum including a non-planar end;
• a second fluid inlet plenum disposed adjacent the first fluid outlet plenum and a second fluid outlet plenum disposed adjacent the first fluid inlet plenum, the second fluid inlet plenum including a non-planar end;
• and
• a tube plate disposed between the second fluid outlet plenum and the first fluid inlet plenum and a tube plate disposed between the first fluid outlet plenum and the second fluid inlet plenum, the first set of heat exchanging passageways defining a first tube-side fluid flow path for a first fluid, the first set of heat exchanging passageways extending from the first fluid inlet plenum to the first fluid outlet plenum, the second set of heat exchanging passageways defining a second tube-side fluid flow path in for a second fluid, the second set of heat exchanging passageways extending from the second fluid inlet plenum to the second fluid outlet plenum, and wherein each of the first set of heat exchanging passageways are in contact against at least one of the second set of heat exchanging passageways,
• wherein the core region includes a metal formed in a casting process about the first set of heat exchanging passageways and the second set of heat exchanging passageways, such that when the casting process is complete, the metal secures the first set of heat exchanging passageways in contact with at least one of the second set of heat exchanging passageways.

A method of fabricating a heat exchanger for exchanging heat between two fluid flows in counter-flow arrangement comprising:

• casting a first set of heat exchanging passageways and a second set of heat exchanging passageways to form a core region, the core region having opposed distal ends and defining a length therebetween, the first set of heat exchanging passageways truncated proximate the opposed distal ends of the core region and the second set of heat exchanging passageways extending a length longer than a length of the first set of heat exchanging passageways, wherein when the casting is complete, the metal secures the first set of heat exchanging passageways in contact against at least one of the second set of heat exchanging passageways;
• casting a tube plate about opposed distal ends of each heat exchanging passageway of the second set of heat exchanging passageways to define a plenum region adjacent the opposed distal ends of the core region, each of the plenum regions including a fluid inlet plenum and a fluid outlet plenum the tube plate disposed therebetween the fluid inlet plenum and the fluid outlet plenum, the fluid inlet plenum and the fluid outlet plenum each including a non-planar end;
• and
• disposing a core shell about the core region and a plenum shell about each of the plenum regions.