Counterflow helical heat exchanger

1. A method of assembling a heat exchanger, comprising the steps of:

providing a tube having first and second ends, a length, an inner diameter and a cross-section incorporating the inner diameter;

providing a thermally conductive tube insert having a length and an outer diameter substantially equal to the inner diameter of the tube, the tube insert having first and second ends and comprising a single helix extending along the length of the tube insert and twisted around a central axis, the helix having an outer edge adapted to contact an inner surface of the tube to create a fluid tight seal when the tube insert is inserted therein;

inserting the tube insert within the tube;

mechanically swaging or compressing the tube onto the outer edge of the helix;

brazing the tube and tube insert to seal the outer edge of the helix to the inner surface of the tube to form fluid-tight first and second fluid flow paths defined between opposing sides of the helix and the inner surface of the tube, respectively; and

providing a plurality of inlet and outlet fluid ports for passage of a first and second fluid into and out of the tube.

2. The method of claim 1 wherein the fluid ports are arranged for counterflow operation whereby the first and second fluids flow in opposite directions.

3. The method of claim 1 wherein the tube insert is inserted within the tube by automation.

4. The method of claim 1 wherein the step of inserting the tube insert within the tube and sealing the tube insert therein further comprises:

sealing the first and second ends of the tube insert to inner surfaces of the first and second tube ends, respectively, such that the first fluid flow path is defined between a first side of the helix and the inner surface of the tube, and the second fluid flow path is defined between a second side of the helix and the inner surface of the tube.

5. The method of claim 1 wherein the helix includes turbulating dimples or ridges on at least one side of the helix.

6. The method of claim 1 further including the steps of:

sealing a second end cap to the tube and tube insert second ends; and

sealing a first end cap to the tube and tube insert first ends.

7. The method of claim 6 wherein the first and second end caps are flat, circular plates and are sealed flush with the ends of the tube and tube insert to prevent fluid mixing inside the heat exchanger.

8. The method of claim 1 wherein the helix has a predetermined pitch, the pitch of the helix defining a length of the first and second fluid flow paths.

9. The method of claim 8 wherein the pitch of the helix is constant along the length of the tube insert.

10. The method of claim 8 further including the step of:

varying the pitch of the helix along the length of the tube insert, wherein decreasing the pitch along at least a portion of the length of the tube insert increases the length of the first and second fluid flow paths, and wherein increasing the pitch along at least a portion of the length of the tube insert increases the flow path area of the first and second fluids.

11. A method of operating a heat exchanger assembly, comprising:

providing a heat exchanger having a tube with first and second ends, a length, an inner diameter and a cross-section incorporating the inner diameter; a thermally conductive tube insert having a length and an outer diameter substantially equal to the inner diameter of the tube, the tube insert comprising a single helix extending along the length of the tube insert and twisted around a central axis, the tube mechanically swaged or compressed onto the outer edge of the helix and brazed to seal the tube insert within the tube to form fluid-tight first and second fluid flow paths defined between opposing sides of the helix and the inner surface of the tube, respectively; and a plurality of inlet and outlet fluid ports for passage of a first and second fluid into and out of the tube;

connecting inlet and outlet fluid lines for a first fluid to a first set of inlet and outlet ports;

connecting inlet and outlet fluid lines for a second fluid to a second set of inlet and outlet ports; and

flowing the first and second fluids through the first and second sets of inlet and outlet ports, respectively, to transfer heat from one fluid to the other.

12. The method of claim 11 wherein the first and second sets of inlet and outlet fluid ports are arranged for counterflow operation whereby the first and second fluids flow in opposite directions through the first and second fluid flow paths.