Radiant coolers and methods for assembling same

1. A method of assembling a radiant cooler, said method comprising:

providing a vessel shell that defines a gas flow passage therein that extends generally axially through the vessel shell;

forming a tube cage including a plurality of cooling tubes defining a plurality of chevron-shaped projections that are coupled together continuously to each said circumferentially-adjacent projection, the plurality of chevron-shaped projections extending circumferentially about a center axis of the tube cage, each chevron-shaped projection including a first side and a second side coupled together at a tip, circumferentially-adjacent pairs of projections coupled together such that a valley is defined between each pair of circumferentially-spaced projections, each of the projection tips being positioned radially outward from each of the valleys;

positioning at least one heat transfer panel within said tube cage, such that said at least one heat transfer panel extends radially inwardly from a tip of one of said chevron-shaped projections towards said center axis;

coupling at least one downcomer in one valley radially outwardly of the tube cage, such that the at least one downcomer extends generally axially between the first side and the second side of one circumferentially-spaced projection; and

orienting the tube cage within the vessel shell such that the tube cage is in flow communication with the flow passage.

2. A method in accordance with claim 1 wherein forming a tube cage further comprises defining a tip with at least one cooling tube, and defining a valley with at least one cooling tube.

3. A method in accordance with claim 1 wherein forming a tube cage further comprises aligning the plurality of tubes at least one of linearly, sinusoidally, and arcuately from each of the tips to each of the valleys.

4. A method in accordance with claim 1 wherein forming a tube cage further comprises aligning the plurality of cooling tubes such that each first side has a first length and each second side has a second length that is substantially equivalent to the first length.

5. A method in accordance with claim 1 wherein forming a tube cage further comprises aligning the plurality of cooling tubes such that each first side has a first length and each second side has a second length that is different than the first length.

6. A tube structure for use in a syngas cooler, said tube structure comprising:

a tube cage comprising a plurality of cooling tubes defining a plurality of chevron-shaped projections, said plurality of chevron-shaped projections coupled together continuously to each said circumferentially-adjacent projection and extending circumferentially about a center axis, each chevron-shaped projection including a first side and a second side coupled together at a tip, circumferentially-adjacent pairs of projections coupled together such that a valley is defined between each said pair of circumferentially-spaced projections, each of said projection tips is positioned radially outward from each of said valleys;

at least one heat transfer panel positioned within said tube cage and formed from a plurality of cooling tubes, said at least one heat transfer panel extends radially inwardly from a tip of one of said chevron-shaped projections towards said center axis; and

a plurality of downcomers spaced radially outward of the circumferentially-spaced projections.

7. A tube structure in accordance with claim 6 wherein each of said tips is defined by at least one cooling tube, each said valley is defined by at least one cooling tube.

8. A tube structure in accordance with claim 6 wherein said first side has a first length, said second side has a second length that is substantially equivalent to said first length.

9. A tube structure in accordance with claim 6 wherein said first side has a first length, and said second side has a second length that is different than said first length.

10. A tube structure in accordance with claim 6 wherein said plurality of downcomers are coupled adjacent each said valley, such that said plurality of downcomers extend generally axially between said first side and said second side of each said pair of circumferentially-spaced projections.

11. A tube structure in accordance with claim 6 wherein said plurality of tubes are aligned at least one of linearly, sinusoidally, and arcuately from each of said tips to each of said valleys.

12. A radiant cooler comprising:

a vessel shell circumferentially-positioned about a center axis at a shell radius; and

a tube cage comprising a plurality of cooling tubes defining a plurality of chevron-shaped projections, said plurality of chevron-shaped projections coupled together continuously to each said circumferentially-adjacent projection and extending circumferentially about a center axis of said tube cage, each chevron-shaped projection including a first and second side coupled together at a tip, circumferentially-adjacent pairs of projections coupled together such that a valley is defined between each said pair of circumferentially-spaced projections;

at least one heat transfer panel positioned within said tube cage and formed from a plurality of cooling tubes, wherein said at least one heat transfer panel extends radially inwardly from a tip of one of said chevron-shaped projections towards said center axis; and

a plurality of downcomers spaced radially outward of the circumferentially-spaced projections.

13. A radiant cooler in accordance with claim 12 wherein said plurality of downcomers are coupled adjacent each said valley, such that said plurality of downcomers extend generally axially between said first side and said second side of each said pair of circumferentially-spaced projections.

14. A radiant cooler in accordance with claim 12 wherein each of said tips is defined by at least one cooling tube, each said valley is defined by at least one cooling tube.

15. A radiant cooler in accordance with claim 12 wherein said plurality of tubes are aligned at least one of linearly, sinusoidally, and arcuately from each of said tips to each of said valleys.

16. A radiant cooler in accordance with claim 12 wherein said first side has a first length, said second side has a second length that is substantially equivalent to said first length.

17. A radiant cooler in accordance with claim 12 wherein said first side has a first length, and said second side has a second length that is different than said first length.