US 20070074602 A1
A method of injecting at least one reagent into a high temperature material includes providing a heat pipe assembly, permitting gravity flow of the liquid working substance from a condenser to an evaporator of the heat pipe assembly through a discrete impermeable liquid return passage therebetween, providing a reagent delivery conduit through the evaporator and emerging at a leading end thereof, conveying the reagent through the reagent delivery conduit and injecting the reagent into the high temperature material. The evaporator of the heat pipe assembly comprises a flow modifier therein adapted to cause swirling of a working substance flow in the evaporator. The condenser is cooled to condense the vaporized working substance received from the evaporator.
1. A method of injecting at least one reagent into a high temperature material, comprising the steps of:
providing a heat pipe assembly having an evaporator and a heat extracting condenser in fluid flow communication therewith, the evaporator comprising a flow modifier therein adapted to cause swirling of a working substance flow in the evaporator, and the condenser being cooled to condense the vaporized working substance received from the evaporator;
providing a discrete, impermeable liquid return passage between the condenser and a leading end of the evaporator;
permitting the flow, by gravity, of the liquid working substance from the condenser to the evaporator through the liquid return passage;
providing a reagent delivery conduit passing through the evaporator and emerging at the leading end thereof; and
conveying the reagent through the reagent delivery conduit and injecting the reagent into the high temperature material.
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This is a Continuation-in-Part application of U.S. patent application Ser. No. 10/925,372 filed Aug. 25, 2004, which is a continuation of International Patent Application No. PCT/CA02/01394 filed Sep. 13, 2002 claiming priority on United States Provisional Patent Application No. 60/358,724 filed on Feb. 25, 2002, the entire contents of each of which are incorporated herein by reference.
The present invention relates generally to a heat pipe, and more specifically to a semi-loop heat pipe having co-current, swirling two phase flow in the evaporator, and an impermeable return line from the condenser.
Heat pipes are devices that employ the evaporation and condensation of a working fluid contained within to effect the transfer of energy from the evaporator where heat is absorbed to the condenser where the heat is released. Heat pipes gained prominence in the early 1960's as superconducting, heat transfer devices as detailed, for example, in U.S. Pat. No. 3,229,759 and 4,485,670. While numerous configurations and applications of heat pipes have been proposed since their initial invention, the basic heat pipe is still viewed as a unit that can transport large quantities of energy over a relatively small temperature gradient.
Heat pipes are containment vessels that are charged with a working substance which is continuously evaporated and condensed as heat is added to the evaporator and removed from the condenser. The rate at which vapor is produced is directly proportional to the rate of heat flowing into the heat pipe. The ability of a heat pipe to efficiently transfer energy rests on the fact that non-condensable gaseous species within the chamber are removed from the heat pipe prior to operation. As such, a heat pipe is evacuated prior to its use as a heat transfer device. By eliminating non-condensable gases from the chamber, the vapor that is generated in the evaporator flows to the condenser down a pressure gradient in much the same way as a pump causes fluid to move through an enclosure. With the presence of non-condensable gases, the vaporized working substance would move by molecular diffusion down a concentration gradient. Given that a pressure driven flow can be orders of magnitude more effective in moving vaporized working substance, heat pipe systems are generally evacuated. Conversely, if the heat pipe chamber develops a leak, the heat pipe will cease to function. Thus, the use of a heat pipe in a high temperature environment can be problematic if the evaporator experiences insufficient cooling as this can cause the containment vessel to be perforated with the subsequent failure of the heat pipe.
Heat pipes can generally be classified into two main categories, namely, those wherein the vapor and liquid flow countercurrent to each other, and those wherein the liquid and vapor flow in a co-current manner. Countercurrent flow heat pipes are well known in the prior art.
Co-current heat pipes are generally referred to as loop heat pipes, examples of which are disclosed in U.S. Pat. Nos. 4,515,209 and 5,911,272, depicted respectively in
While both loop and non-loop (i.e. countercurrent) heat pipes have been used in a number of products and applications, they have not been incorporated in units where high heat fluxes at high operating temperatures are encountered and they are generally not used in large scale units. This is largely because such systems are amenable to failure of the containment material that forms the heat pipe. In order to ensure that the containment vessel has durability and a long life, it is necessary to have the entire evaporator of the heat pipe unit adequately cooled by the working substance in the unit. This has not been possible as yet with the heat pipes of the prior art.
Thus, insufficient cooling of even a relatively small region (e.g. 10 mm2) can lead to the perforation and subsequent destruction of the heat pipe unit. Heat pipes of the prior art have rarely been intended for use in applications involving high operating temperatures, and as such, destruction of a heat pipe chamber as a result of exposure to elevated temperatures has never been adequately addressed.
A controllable heat pipe is described in U.S. Pat. No. 5,159,972 comprising a reservoir for the liquid and a separate return line to the top of the evaporator, as shown in
The three main limitations of prior art heat pipes that must be overcome to make their use in high temperature applications feasible are: film boiling on the evaporator walls, levitation of the liquid returning to the evaporator, and configurational complexity of a loop heat pipe for certain applications.
The levitation of liquid from the leading end of the evaporator will reduce heat transfer efficiency and will,if the temperatures are high enough, cause the heat pipe to fail as a result of dry-out. The levitation of liquid is of greatest concern in large scale units where the length of the evaporator can be sizeable. In such units the refluxing of liquid down to the bottom of the evaporator can be a major concern because the total heat load on the unit can be large even if the heat flux is moderate. Since the heat load manifests itself as a vapor flow, the vapor velocity at the top of the evaporator of a large scale unit can be enough to create some degree of fluidization of the liquid.
The other principle difficulty with using heat pipes in high heat flux applications is the onset of film boiling on the evaporator walls. As is well known to those skilled in the art, this can reduce the rate of heat extraction by as much as an order of magnitude. This dramatically reduces the heat transfer efficiency and, in some cases, may lead to the destruction of the evaporator containment walls.
One possible use for heat pipes is in a reagent delivery unit such as a lance. U.S. Pat. No. 5,310,966 describes a heat pipe lance, or tuyere. However, the heat pipe lance of U.S. Pat. No. 5,310,966 fails to teach how to eliminate the levitation of liquid from the leading end of the evaporator or how to eliminate the formation of a stable vapor film on the inner walls of the evaporator.
Loop heat pipes can overcome the issue of entrainment, however, loop heat pipes are often not viable for many practical applications because of their configurational complexity, wherein the return loop pipe is run outside the main heat pipe body which significantly increases space requirements of the heat pipe. Nevertheless, as with countercurrent heat pipes, the problem of film boiling on the evaporator surfaces nevertheless remains.
The mechanism for evaporation remains an important limiting factor in a heat pipe, and especially for high heat flux applications. If the working substance is of low thermal conductivity and the heat flux is relatively high, the working substance will experience boiling at the interface between the liquid and the heat source. If the generation of vapor is sufficiently intense, a stable vapor film will ultimately form between the liquid phase of the working fluid and the evaporator wall. This vapor film will greatly inhibit heat transfer. The evaporator has then attained its boiling limit, and the subsequent result of continued exposure to the heat flux can be overheating of the evaporator walls and possible failure of the heat pipe.
Therefore, in accordance with an aspect of the present invention, there is provided a method of injecting at least one reagent into a high temperature material, comprising the steps of: providing a heat pipe assembly having an evaporator and a heat extracting condenser in fluid flow communication therewith, the evaporator comprising a flow modifier therein adapted to cause swirling of a working substance flow in the evaporator, and the condenser being cooled to condense the vaporized working substance received from the evaporator; providing a discrete, impermeable liquid return passage between the condenser and a leading end of the evaporator; permitting the flow, by gravity, of the liquid working substance from the condenser to the evaporator through the liquid return passage; providing a reagent delivery conduit passing through the evaporator and emerging at the leading end thereof; and conveying the reagent through the reagent delivery conduit and injecting the reagent into the high temperature material.
Further features and advantages of the present invention will become apparent from the following detailed description, taken in combination with the appended drawings, in which:
The heat pipe of the present invention is comprised principally of an evaporator, a coupling element, and a condenser, and comprises generally two principle embodiments, whose main classes of applications are as an energy extractor as shown in
The evaporator portion 12 sits in a hot, and sometimes harsh, environment. It can include one or more conduits for transporting a reagent when the heat pipe unit is used as an injection device, as shown in
The condenser 16, positioned at a higher elevation than the evaporator 12, is the portion of the heat pipe in which the vapor phase of the working substance is condensed. Condensation of the vapor is achieved by configuring the condenser as a heat exchanger. External cooling of the condenser is achieved by using internal cooling passages as well as by using a cooling jacket on the external walls of the condenser, which will be discussed further below. The condenser is chosen such that its cross-sectional area can be substantially larger than that of the evaporator. In this way, the levitation of liquid within the condenser is completely eliminated.
The two phase flow of the working fluid, that is generated in the evaporator 12 as a result of the heat to which it is exposed, moves upward through the coupling element 14 into the condenser 16 with outer body walls 28. The condenser confines and cools the vapor/liquid working substance, causing the two phase fluid to condense into liquid and settle in the reservoir portion 30, formed between the condenser outer walls 28 and the extension wall 32 of the upper portion of the coupling element 14. Liquid collected in the condenser 16 then flows by gravity through the drain hole 34 and into the upper return line 36, which can be a flexible line. The return line 36 is joined to a vent line 38 at a ‘T’ junction 40. The vent line 38, which can be a flexible line, connects the upper return line to the top of the condenser. In this way, any vapor that infiltrates into the return line is diverted into the vent line and released in the low pressure region of the condenser. The upper return line 36 then joins into the impermeable lower return line 20, to deliver liquid working substance back to the leading end 21 of the evaporator 12 as a separate stream which is shielded from the ascending flow and is thus not affected by it. The return line 20 terminates near the leading end 21 of the evaporator 12. A preferred termination distance is two times the internal diameter of the return line 20. This discontinuity at the discharge end of the return line of the heat pipe has resulted in the present invention being referred to as a ‘semi-loop’ heat pipe.
By incorporating a solid wall return line within the confines of the evaporator, it is possible to return liquid to the leading end without adopting a conventional loop configuration. Maintaining an adequate liquid head in the return line and the reservoir, coupled with a sufficiently high liquid velocity at the discharge end of the return line, minimizes the quantity of vapor that can enter the return line. Moreover, fitting the return line with a vent line is sufficient to provide a stable flow of liquid to the evaporator.
A flow modifier 24 is located within the evaporator 12 along the inner surface 23 of the evaporator wall 22. The flow modifier 24 is preferably generally helical in shape, and preferably comprises one of a helical swirler, a twisted tape and a helical spring, as depicted in
The type and dimensions of the swirling flow modifier 24 to use in a given heat pipe is determined by several parameters for a given application such as the rate at which vaporized working substance is generated per unit of time and the cross-sectional area of the heat pipe.
To ensure that all the evaporator walls are contacted by liquid, it is necessary to return liquid to the bottom of the evaporator, preferably through the core of the evaporator in the eye of the swirling flow where the pressure is lowest. It is preferable that the excess quantity of liquid that is returned be as much as 10 times or more than that required for vaporization. This will ensure that the centrifugal force arising from the swirling flow maintains the evaporator walls completely covered with liquid. For example, a water-based heat pipe that is extracting 4 kW will cause about 2 g/s of water to be vaporized. The return line for such a unit must therefore return at minimum 2 g/s, with a significantly higher return rate (10-20 g/s) being preferred.
To dissipate the heat that is transported from the evaporator to the condenser by the vapor molecules, an external coolant, for example air, water or oil, is used. Referring to
The coolant leaving the cooling tubes 46 enters a discharge header 50 whereupon the coolant is diverted into a jacket formed by outer member 52 and the condenser wall 28. The coolant leaves the jacket via port 54. The outer jacket is also fitted with a spring type, swirling device 56 to enhance turbulence and thus heat transfer. In an alternate embodiment of the condenser, the cooling tubes 46 along with the inlet header 44 and the outlet header 50 can be eliminated. The cooling would in this case be achieved by the flow of coolant in the jacket formed by the condenser wall 28 and the surrounding outer member 52. In another alternate embodiment, the jacket could also be eliminated and natural or forced cooling from the condenser wall 28 would provide all the necessary heat dissipation. One skilled in the art would be able to determine which configuration is appropriate for a given system.
The condenser also incorporates a filling and evacuation tube 58. This is used, as the name implies, to charge the heat pipe with the working fluid, and to evacuate any non-condensable gases. In addition, the condenser can be fitted with a thermocouple well 60 which can house one or more thermocouples used to monitor the operation of the heat pipe. Both the evacuation tube 58 and the thermocouple well 60 are made in such a way as to compensate for thermal expansion effects.
As one of the significant limitations of the prior art heat pipes used in high heat flux applications was the early onset of film boiling in the evaporator, the flow modifying swirler of the present invention, which substantially resolves this problem, is an important preferred feature of the present heat pipe, and as such was experimentally tested to ensure it provided the desired results.
To illustrate the effectiveness of a simple twisted tape flow modifier, two identical heat pipes with water as the working substance were tested in the following manner. The evaporators of the heat pipes were immersed in molten zinc and the zinc was then allowed to freeze and cool. The zinc was then reheated and the rate of heat extraction by each heat pipe was measured as a function of the zinc temperature. The results from this test are shown in
While the heat pipe of the present invention can, much as those of the prior art, have a wick 163 located on the inner wall surface of the evaporator as shown in
The upper return line 36 can be fitted with a valve 41, as shown in
To illustrate this on/off feature of the heat pipe, the cooling of a tool steel casting mold was tested with a water based heat pipe of the present invention. The mold was such that it was made of 2 symmetrical halves, one half having a vertical heat pipe of 25 mm diameter. The other half of the mold did not have a heat pipe. Molten aluminum was poured into the mold. The results are shown in
In a slight variation of the preferred embodiment of the present invention, the evaporator wall 22 can formed by drilling a hole into a solid material, and then attaching the coupling element 14 directly to the hole. The hole therefore constitutes the evaporator of the heat pipe. Such a configuration can be of advantage over the insertion of a heat pipe into a cavity which can give rise to a sizeable contact resistance. By making the drilled cavity the evaporator of the heat pipe, one can eliminate this contact resistance. Possible applications of this configuration include the cooling of solid masses such as casting molds, furnace walls, tap holes, engines, heat exchangers and the like.
As originally mentioned, there are two main classes of applications envisaged for the present invention: as an energy extractor and as an injection unit as shown in
Thus, in the embodiment of the present invention depicted in
The evaporator 112 comprises a central reagent conduit 170 which is surrounded by a working fluid return line 120. While the return line 120 does not necessarily have to fit over the reagent conduit 170 and can be a separate pipe which is located next to the conduit as is shown in
The choice of wicks and flow modifiers is dependent on the heat pipe/working substance combination to be used. For high velocity flows of the working substance, a spring is preferred, while for low velocity systems, a helical shape is better. In both cases, the return line assembly passes through the center of the flow modifier. Wicks can be made from screen or sintered materials with pore size and porosity being chosen by one skilled in the art as required.
When the return line is a separate line, such as in
While it appears that a return line that is separated from the discrete reagent delivery conduit 172 has the disadvantage that the liquid is not cooled by the reagent, it does, however, have the advantage that liquid can flow more easily through this configuration as the drag of the walls is less for a given cross-sectional area. Thus, heat pipe units of relatively small size should use the separated return and reagent delivery lines shown in
The condenser 116 is a heat exchanger, and is substantially similar to the condenser 16 as previously described. While a number of configurations are viable, the preferred configuration is as shown in
A distribution header 144 for the reagent sits below the condenser chamber. It is fed reagent through feed port 142. The reagent then flows through a collection of cooling tubes 146. Each of the tubes is fitted with a twisted tape insert 148 to enhance the heat transfer by causing the reagent to swirl. In this way the effect of centrifugal force pushes denser colder reagent up against the walls where it can absorb heat from the condensing working substance.
The reagent leaving the cooling tubes 146 enters a discharge header 150 whereupon the reagent is diverted into a jacket formed by surrounding outer member 152 and the condenser wall 128. The reagent leaves the jacket via exit port 154 and flows through tubing 155 which connects it to the top end of the reagent delivery conduit 170. The outer jacket is also fitted with a spring, swirling device 156 to enhance turbulence and thus heat transfer.
The condenser also incorporates a filling and evacuation tube 158. In addition, the condenser is fitted with a thermocouple well 160 which can house one or more thermocouples that are used to monitor the operation of the heat pipe.
While the description of the injection heat pipe unit for conveying reagent has focused on the angled unit shown in
In some cases, it may be desirable to have more than the reagent cool the condenser. This condition can arise if the heat load on the evaporator is large enough that cooling with only one reagent is not sufficient. To overcome this, the condenser can be divided into multiple cooling circuits. An example of such a condenser is shown in
The choice of working substance to use in a heat pipe unit irrespective of whether or not the unit is used to carry reagent, will depend on several factors including the heat flux and the operating temperatures. While many choices for working substances are possible, the preferred working substance for high heat fluxes is sodium or another alkali metal such as potassium. With sodium the heat pipe unit can handle high heat fluxes while operating at a temperature of about 600° C. If the operating temperature is to be substantially less, then water or organic substances such as thermex can be used as the working substance.
Another possible working substance for use in the heat pipes described above is sulphur. Sulphur can be quite effective as a working substance in all possible applications for the present heat pipe (for example either when as an energy extraction heat pipe 10 as shown in
The heat pipe unit must be evacuated during the preparation stage, such that much of the non-condensable, inert gases within the unit are extracted from the heat pipe before it is sealed. When there are no inert gases in the unit, one can use the maximum area for condensation. Moreover, the vaporized working substance molecules are forced into the condenser by the ensuing pressure differentials that arise because of the ongoing vaporization and condensation processes.
The quantity of working substance to charge into the heat pipe may vary. While the prior art generally advocates charging a relatively small quantity, the present invention allows for the charging of an excess quantity. The minimum amount of working substance to be charged is such as to ensure that there is sufficient coverage of the evaporator during operation. The maximum amount to use is dictated by the size of the reservoir. The entire quantity of working substance should fit inside the reservoir. The preferred quantity to charge is 50-90% of the reservoir volume, an amount that approximately equals the volume of the evaporator.
The choice of coolant for the condenser will depend on several basic heat transfer considerations. While air is the preferred choice, it is also possible to use water or oil as the coolant. Ultimately the choice will be determined by such factors as availability and economics. As a general rule, if the heat pipe is operated at a high temperature then a gas such as air is a viable coolant. If, however, the pipe is operated at a low temperature then a liquid such as water may be a more desirable coolant.