Compact Heat Exchangers in HVAC systems

ASHRAE meeting in Mxico City 2009-01-13

Martin Crona Alfa Laval Lund AB

Content
Topics of the presentation

Compact heat exchangers for HVAC Heat transfer characteristics CHE in HVAC applications CHE Components Design guidelines

Alfa Laval

Slide 2

Compact heat exchangers in HVAC systems

Enables high energy efficiency Close temperature approach Small temperature losses Increased temperature drop Fast response times at regulation

Limited footprint Compact design High thermal efficiency

Easy service Openable for mechanical cleaning Expansion of capacity possible

Alfa Laval

Slide 3

Compact heat exchangers

Gasketed plate heat exchangers

Brazed Heat Exchangers Fusion bonded heat exchangers

All-welded heat exchangers

Alfa Laval

Slide 4

Compact heat exchanger

Alfa Laval

Slide 5

PHE basic components

Carrying bar

Frame plate

Pressure plate

Tightening bolts

Plate pack

Gasketed plate heat exchanger

Pack of corrugated plates sealed by gaskets Possible to open for cleaning and extension Pressure range 0-30 barg Temperature range -25 C to 180 C Flexible connections sizes (20mm) to 500mm Flexibility in plate and sealing material selection

Alfa Laval

Slide 7

Brazed heat exchangers

BHE - design

Connections

BHE = Brazed Heat Exchanger Compact design Corrugated stainless steel plates Cupper as brazing material Main use in heating and refrigeration duties Max temperature: 225 C Max pressure: 32 barg

Frame plate

Foil

Heat transfer plate

Alfa Laval

Slide 8

Fusion bonded heat exchanger

FHE - design

FHE = Fusion bonded Heat Exchanger Compact design 100% stainless steel Thin corrugates plates Stainless steel as bonding material Max temperature: 550 C Max pressure 32 barg Main use in ammonia and corrosive medias

Alfa Laval

Slide 9

All-welded heat exchanger

Gasket free HE for high temperatures or pressures Many types exist

Plate type

Plate types Plate & Shell Openable block type Spiral heat exchangers

Steam condensation is primary application in HVAC Welded HE main use is in chemical industry

Plate & shell

Alfa Laval Slide 10

Compact heat exchanger

Characteri Feature stic
Flow / Capacity Temperature Pressure Serviceability Cost efficiency Risk of fatigue Medias to use
(only relevant in steam duties)

PHE
20mm 500mm 180 C 30barg Yes 3 Excellent Flexibility in plate or gasket material -all duties within temp and pressure range

BHE
20mm 100mm 225 C 32barg No 1 OK Limited by cupper -small capacities -clean medias -freon duties

FHE
20mm 100mm 550 C 32 barg No 2 OK Limited by stainless steel -ammonia duties -tap water

WHE
50mm 250mm* 300 C* 60barg* No / partly* 4-5* OK* Flexible in plate material -steam condensation

Connection size Max temperature Max design pressure Mechanical cleaning Cost ratio Fatigue resistance Corrosion resistance

Primary HVAC applications

Alfa Laval

*depend on WHE type

Slide 11

HVAC applications

Cooling interchanger Free cooling Pressure breaker Condensor protection Ice storage District cooling Heat recovery Domestic hot water Pool Solar heating

Alfa Laval

Slide 12

Efficient heat transfer

Cold fluid in at T2 In Mass flowrate m2 Cold fluid out at T2 Out Mass flowrate m2 Hot fluid in at T1 In Mass flowrate m1 Hot fluid out at T1 Mass flowrate m1 Heat released by the hot fluid: Heat absorbed by the cold fluid: No heat loss Heat transfer equation Pressure drop
Out

Definitions Q = Heat load, kBTU/h (W) (rate of heat transfer) m = Mass flow rate, lb/s(kg/s) Cp = Specific heat, J/kg C (the energy needed to heat 1 kg of the fluid with 1 C)

Q1=m1*Cp1*(T1 In-T1 Out) Q2=m2*Cp2*(T2 Out -T2 In) Q1 = Q2 Q=u*A*LMTD P=k*v2

Heat transferred in a HE
The temperature profile at one point of the plate wall
T1, Bulk temperature on hot side Hot side Flow direction T3 T4 Flow direction Cold side T2, Bulk temperature on cold side Wall

1/u = 1/

hot +

1/

cold +

More turbulence Thinner laminar film Increased u-value Better Heat Transfer

Close temperature approach

Thermal definitions
Water return from house Thot,in
1

T,in Water to A/C in house

2

Tcold,out Cold water to chiller T,hot

Thot,out Ex. Tcold,in Cold water from chiller

LMTD =

1 2 1 ln 2

NTU hot = hot =

Thot ,in Thot ,out LMTD

NTU cold = cold =

Tcold ,in T cold ,out LMTD

Higher NTU means more difficult heat transfer LMTDs possible down to 1 F Normal NTU in HVAC Cooling 6-7 NTU in district cooling upto 9
Alfa Laval Increased

NTU means increased area

Slide 15

Energy efficiency
88F 90F 40F 47F 45F 47F

78F

80F

Qcond = 2200 kBTU/h Direct Qcool (kBTU/h) LMTD ( F) Qchiller (kW) Loss 1700 146 -

COP = 3,4

50F 57F 55F

57F

Q = 1700 kBTU/h S&T 1700 7 174 -18%

PHE 1700 2 154 -5%

High energy efficiency with PHE Less loss on condensor side

Alfa Laval Slide 16

HE comparison
Compact heat exchanger advantages

6ft 5ft

Smaller foot print Less weight Less fouling risk No fouling factor needed in design Small hold-up volume Easier maintenance Easier installation

20ft
Alfa Laval Slide 17

System optimization
46F 45F 47F

55F 58F 56F

57F 60F

Alfa Laval

Q = u * A * LMTD Smaller LMTD give larger heat exchanger

LMTD 2 down to 1 give A up 250% P down from 7 to 3,5 psig give A up 40% 3 F larger T mean 25% smaller Slide 18 flow

Smaller pressure drop give larger heat exchanger Larger temperature drop enables smaller flow

Energy savings with chiller by-pass

45F 88F 90F 45F 47F

Qcond = 2200 kBTU/h

78F 58F

80F

COP = 3,4

58F

60F

Q = 1700 kBTU/h

Low temperatures in winter time for cooling source

Alfa Laval

Low wet bulb temperature in cooling towers Low water temperature in water cooling Chiller by-pass is possible Pay-back often within 1-2 years Slide 19

When cooling temperature go below A/C temperature

156 kW is saved

Venice Casino in Las Vegas

Alfa Laval

Slide 20

PHE full serviceability

Carrying bar

Frame plate

Pressure plate

Tightening bolts

Plate pack

Corrosion factors
In cooling and heating there is with some water qualities risk of crevice corrosion and pitting corrosion. Basic condition is that free oxygen and chlorides must be present and the corrosion risk depends on the factors below

Factor Chloride content Temperature pH Level

Change

Influence

Alfa Laval

Slide 22

Plate - materials

Standard materials and typical uses

AISI 304 Typically in clean water-water duties Example, up to 50 ppm chlorides at 50 C AISI 316 Typically in water-water duties Example, up to 250 ppm chlorides at 50 C 254 SMO (high-alloy stainless steel) Many uses including high-chloride water-water duties Example, up to 6000 ppm chlorides at 50 C Titanium Most frequent use is for sea water (3.5% chlorides) Example, up to 130 C in sea water

Gasket - materials
The choice of rubber material depends on
Temperature Required lifetime Media

Rubber materials change properties due to

Time - the rubber relaxes Temperature - the rubber deteriorates Hardening by attack of oxidising agents (e.g., oxygen in air) Swelling or softening by absorption of chemicals in the fluids

Common gasket types

Nitrile EPDM FKMT

Protecting the heat exchanger

F ilte r

A filter for industrial cooling systems using low-quality water The Filter operates as an integral part of a cooling system to remove debris which can foul and clog a plate heat exchanger or a tubular condenser.

Compact heat exchangers in HVAC systems

Enables high energy efficiency Close temperature approach Small temperature losses Increased temperature drop Fast response times at regulation

Limited footprint Compact design High thermal efficiency

Easy service Openable for mechanical cleaning Expansion of capacity possible

Alfa Laval

Slide 26

Thank you! Questions?

Alfa Laval

Slide 27