Method and apparatus for minimizing adverse effects of thermal expansion in a heat exchange reactor

A heat exchange reactor comprising:

• a housing;
• a plurality of tubes configured to carry a first fluid, said plurality of tubes being mounted within said housing;
• a baffle having a plurality of holes receiving said plurality of tubes, said baffle being configured to guide a second fluid provided within said housing to flow in a direction generally perpendicular to said plurality of tubes;
• means for minimizing adverse effects of thermal expansion of at least one of said baffle and said plurality of tubes;
• and
• a first header plate mounting first ends of said plurality of tubes within said housing and a second header plate mounting second ends of said plurality of tubes within said housing,
• wherein said means for minimizing adverse effects of thermal expansion comprises means for reducing a differential thermal expansion between said first header plate, said second header plate, and said baffle,
• wherein said means for minimizing the adverse effects of thermal expansion further comprises means for providing a thermal insulation zone along a length of said plurality of tubes at a large temperature gradient zone within said heat exchange reactor.

A heat exchange reactor comprising:

• a housing;
• a plurality of tubes configured to carry a first fluid, said plurality of tubes being mounted within said housing;
• a baffle having a plurality of holes receiving said plurality of tubes, said baffle being configured to guide a second fluid provided within said housing to flow in a direction generally perpendicular to said plurality of tubes;
• means for minimizing adverse effects of thermal expansion of at least one of said baffle and said plurality of tubes;
• and
• a first header plate mounting first ends of said plurality of tubes within said housing and a second header plate mounting second ends of said plurality of tubes within said housing,
• wherein said means for minimizing adverse effects of thermal expansion comprises means for reducing a differential thermal expansion between said first header plate, said second header plate, and said baffle,
• further comprising:
• a heat transfer fin in contact with at least one of said plurality of tubes, said heat transfer fin being configured to contact the second fluid provided within said housing;
• and
• means for minimizing adverse effects of thermal expansion of said heat transfer fin.

A heat exchange reactor comprising:

• a housing;
• a plurality of tubes configured to carry a first fluid, said plurality of tubes mounted within said housing;
• a heat transfer fin in contact with at least one of said plurality of tubes, said heat transfer fin being configured to contact a second fluid provided within said housing;
• means for minimizing adverse effects of thermal expansion of at least one of said heat transfer fin and said plurality of tubes;
• and
• a first header plate mounting first ends of said plurality of tubes within said housing and a second header plate mounting second ends of said plurality of tubes within said housing,
• wherein said means for minimizing adverse effects of thermal expansion comprises means for reducing a differential thermal expansion between said first header plate, said second header plate, and said heat transfer fin,
• wherein said means for minimizing the adverse effects of thermal expansion further comprises means for providing a thermal insulation zone along a length of said plurality of tubes at a large temperature gradient zone within said heat exchange reactor.

A heat exchange reactor comprising:

• a housing;
• a plurality of tubes configured to carry a first fluid, said plurality of tubes mounted within said housing;
• a baffle having a plurality of holes receiving said plurality of tubes, said baffle being configured to guide a second fluid provided within said housing to flow in a direction generally perpendicular to said plurality of tubes;
• a first header plate mounting first ends of said plurality of tubes within said housing and a second header plate mounting second ends of said plurality of tubes within said housing;
• and
• a thermal insulator defining a thermal insulation zone along a length of said plurality of tubes at a large temperature gradient zone within said heat exchange reactor, said thermal insulator having a plurality of holes receiving said plurality of tubes,
• wherein said housing has a first temperature zone and a second temperature zone, said first temperature zone and said second temperature zone being at different temperatures, wherein said first header plate is provided within said first temperature zone and said baffle is provided within said second temperature zone, and
• wherein said first header plate is made of a material having a first coefficient of thermal expansion and said baffle is made of a material having a second coefficient of thermal expansion, said first coefficient of thermal expansion being different from said second coefficient of thermal expansion.

A heat exchange reactor comprising:

• a housing;
• a plurality of tubes configured to carry a first fluid, said plurality of tubes mounted within said housing;
• a baffle having a plurality of holes receiving said plurality of tubes, said baffle being configured to guide a second fluid provided within said housing to flow in a direction generally perpendicular to said plurality of tubes;
• and
• a first header plate mounting first ends of said plurality of tubes within said housing and a second header plate mounting second ends of said plurality of tubes within said housing,
• wherein said housing has a first temperature zone and a second temperature zone, said first temperature zone and said second temperature zone being at different temperatures, wherein said first header plate is provided within said first temperature zone and said baffle is provided within said second temperature zone, and
• wherein said first header plate is made of a material having a first coefficient of thermal expansion and said baffle is made of a material having a second coefficient of thermal expansion, said first coefficient of thermal expansion being different from said second coefficient of thermal expansion,
• wherein said first temperature zone is at a temperature that is lower than a temperature of said second temperature zone, and wherein said second coefficient of thermal expansion is less than said first coefficient of thermal expansion.

A heat transfer reactor comprising:

• a housing;
• a plurality of tubes configured to carry a first fluid, said plurality of tubes mounted within said housing;
• a baffle having a plurality of holes receiving said plurality of tubes, said baffle being configured to guide a second fluid provided within said housing to flow in a direction generally perpendicular to said plurality of tubes;
• and
• a first header plate mounting first ends of said plurality of tubes within said housing and a second header plate mounting second ends of said plurality of tubes within said housing,
• wherein said housing has a first temperature zone and a second temperature zone, said first temperature zone and said second temperature zone being at different temperatures, wherein said first header plate is provided within said first temperature zone and said baffle is provided within said second temperature zone, and
• wherein said first header plate is made of a material having a first coefficient of thermal expansion and said baffle is made of a material having a second coefficient of thermal expansion, said first coefficient of thermal expansion being different from said second coefficient of thermal expansion,
• further comprising a heat transfer fin in contact with one tube of said plurality of tubes, said heat transfer fin not being attached to another tube of said plurality of tubes, said heat transfer fin being configured to contact the second fluid provided within said housing.

A heat exchange reactor comprising:

• a housing;
• a plurality of tubes configured to carry a first fluid, said plurality of tubes mounted within said housing;
• a heat transfer fin in contact with at least one of said plurality of tubes, said heat transfer fin being configured to contact a second fluid provided within said housing;
• a first header plate mounting first ends of said plurality of tubes within said housing and a second header plate mounting second ends of said plurality of tubes within said housing;
• and
• a thermal insulator defining a thermal insulation zone along a length of said plurality of tubes at a large temperature gradient zone within said heat exchange reactor, said thermal insulator having a plurality of holes receiving said plurality of tubes,
• wherein said housing has a first temperature zone and a second temperature zone, said first temperature zone and said second temperature zone being at different temperatures, wherein said first header plate is provided within said first temperature zone and said heat transfer fin is provided within said second temperature zone, and
• wherein said first header plate is made of a material having a first coefficient of thermal expansion and said heat transfer fin is made of a material having a second coefficient of thermal expansion, said first coefficient of thermal expansion being different from said second coefficient of thermal expansion.

A heat exchange reactor comprising:

• a housing;
• a plurality of tubes configured to carry a first fluid, said plurality of tubes mounted within said housing;
• a heat transfer fin in contact with at least one of said plurality of tubes, said heat transfer fin being configured to contact a second fluid provided within said housing;
• and
• a first header plate mounting first ends of said plurality of tubes within said housing and a second header plate mounting second ends of said plurality of tubes within said housing,
• wherein said housing has a first temperature zone and a second temperature zone, said first temperature zone and said second temperature zone being at different temperatures, wherein said first header plate is provided within said first temperature zone and said heat transfer fin is provided within said second temperature zone,
• wherein said first header plate is made of a material having a first coefficient of thermal expansion and said heat transfer fin is made of a material having a second coefficient of thermal expansion, said first coefficient of thermal expansion being different from said second coefficient of thermal expansion,
• wherein said first temperature zone is at a temperature that is lower than a temperature of said second temperature zone, and
• wherein said second coefficient of thermal expansion is less than said first coefficient of thermal expansion.

A heat transfer reactor comprising:

• a housing;
• a plurality of tubes configured to carry a first fluid, said plurality of tubes mounted within said housing;
• a heat transfer fin in contact with at least one of said plurality of tubes, said heat transfer fin being configured to contact a second fluid provided within said housing;
• and
• a first header plate mounting first ends of said plurality of tubes within said housing and a second header plate mounting second ends of said plurality of tubes within said housing,
• wherein said housing has a first temperature zone and a second temperature zone, said first temperature zone and said second temperature zone being at different temperatures, wherein said first header plate is provided within said first temperature zone and said heat transfer fin is provided within said second temperature zone,
• wherein said first header plate is made of a material having a first coefficient of thermal expansion and said heat transfer fin is made of a material having a second coefficient of thermal expansion, said first coefficient of thermal expansion being different from said second coefficient of thermal expansion, and
• wherein said heat transfer fin is not attached to another tube of said plurality of tubes.

A heat exchange reactor comprising:

• a housing;
• a plurality of tubes configured to carry a first fluid through said housing in a single-pass arrangement, said plurality of tubes mounted within said housing;
• and
• a baffle having a plurality of holes receiving said plurality of tubes, said baffle being configured to guide a second fluid provided within said housing to flow in a direction generally perpendicular to said plurality of tubes, said plurality of holes is configured in an array, said array having a center,
• wherein said plurality of holes have predetermined outlines that differ in at least one of size and shape depending upon a distance of a respective hole from said center of said array to minimize mechanical interference between said baffle and a respective tube in both an operational state of said heat exchange reactor and a non-operational state of said heat exchange reactor.

A heat exchange reactor comprising:

• a housing;
• a plurality of tubes configured to carry a first fluid, said plurality of tubes mounted within said housing, said plurality of holes are configured in an array, said array having a center;
• and
• a baffle having a plurality of holes receiving said plurality of tubes, said baffle being configured to guide a second fluid provided within said housing to flow in a direction generally perpendicular to said plurality of tubes,
• wherein said plurality of holes have predetermined outlines that differ in at least one of size and shape depending upon a distance of a respective hole from said center of said array to minimize mechanical interference between said baffle and a respective tube in both an operational state of said heat exchange reactor and a non-operational state of said heat exchange reactor, wherein a first hole of said baffle is provided closer to said center of said array than a second hole of said baffle, and wherein said first hole has a predetermined size that is smaller than a predetermined size of said second hole.

A heat exchange reactor comprising:

• a housing;
• a plurality of tubes configured to carry a first fluid, said plurality of tubes mounted within said housing;
• a first header plate mounting first ends of said plurality of tubes within said housing and a second header plate mounting second ends of said plurality of tubes within said housing;
• and
• a thermal insulator defining a thermal insulation zone along a length of said plurality of tubes at a large temperature gradient zone within said heat exchange reactor, said thermal insulator having a plurality of holes receiving said plurality of tubes,
• wherein said first header plate is made of a material having a first coefficient of thermal expansion and said baffle is made of a material having a second coefficient of thermal expansion, said first coefficient of thermal expansion being different from said second coefficient of thermal expansion.

A method of minimizing adverse effects of thermal expansion within a heat exchange reactor, the heat exchange reactor including a housing, a plurality of tubes mounted within the housing and configured to carry a first fluid, a baffle having a plurality of holes receiving the plurality of tubes, the baffle being configured to guide a second fluid provided within the housing to flow in a direction generally perpendicular to the plurality of tubes, and a first header plate mounting first ends of the plurality of tubes within the housing and a second header plate mounting second ends of the plurality of tubes within the housing, wherein the housing has a first temperature zone and a second temperature zone, said method comprising the step of:

• reducing a differential thermal expansion between the first header plate, the second header plate, and the baffle by selecting material for the first header plate, the second header plate, and baffle having predetermined coefficients of thermal expansion based upon location of the material within the first temperature zone or the second temperature zone,
• wherein the first header plate is provided within the first temperature zone and the baffle is provided within the second temperature zone,
• wherein the first header plate is made of a material having a first coefficient of thermal expansion and the baffle is made of a material having a second coefficient of thermal expansion,
• wherein the first temperature zone is at a temperature that is lower than a temperature of the second temperature zone, and
• wherein the second coefficient of thermal expansion is less than the first coefficient of thermal expansion.

A method of minimizing adverse effects of thermal expansion within a heat exchange reactor, the heat exchange reactor including a housing, a plurality of tubes mounted within the housing and configured to carry a first fluid, a heat transfer fin in contact with at least one of the plurality of tubes, the heat transfer fin being configured to contact a second fluid provided within the housing, and a first header plate mounting first ends of the plurality of tubes within the housing and a second header plate mounting second ends of the plurality of tubes within the housing, wherein the housing has a first temperature zone and a second temperature zone, said method comprising the step of:

• reducing a differential thermal expansion between the first header plate, the second header plate, and the heat transfer fin by selecting material for the first header plate, the second header plate, and heat transfer fin having predetermined coefficients of thermal expansion based upon location of the material within the first temperature zone or the second temperature zone,
• wherein the first header plate is provided within the first temperature zone and the heat transfer fin is provided within the second temperature zone,
• wherein the first header plate is made of a material having a first coefficient of thermal expansion and the heat transfer fin is made of a material having a second coefficient of thermal expansion,
• wherein the first temperature zone is at a temperature that is lower than a temperature of the second temperature zone, and
• wherein the second coefficient of thermal expansion is less than the first coefficient of thermal expansion.

A method of minimizing adverse effects of thermal expansion within a heat exchange reactor, the heat exchange reactor including a housing, a plurality of tubes mounted within the housing and configured to carry a first fluid, a heat transfer fin in contact with at least one of the plurality of tubes, a first header plate mounting first ends of the plurality of tubes within the housing, and a second header plate mounting second ends of the plurality of tubes within the housing, the heat transfer fin being configured to contact a second fluid provided within the housing, said method comprising the step of:

• thermally connecting the heat transfer fin to one tube of the plurality of tubes wherein the heat transfer fin is not attached to another tube of the plurality of tubes,
• wherein the housing has a first temperature zone and a second temperature zone, the first temperature zone and the second temperature zone being at different temperatures,
• wherein the first header plate is provided within the first temperature zone and the heat transfer fin is provided within the second temperature zone, and
• wherein the first header plate is made of a material having a first coefficient of thermal expansion and the heat transfer fin is made of a material having a second coefficient of thermal expansion, the first coefficient of thermal expansion being different from the second coefficient of thermal expansion.