HEAT EXCHANGER

Heat Exchangers
A device whose primary purpose is the transfer of energy between two fluids is named a Heat Exchanger.

Applications of Heat Exchangers

Heat Exchangers prevent car engine overheating and increase efficiency Heat exchangers are used in Industry for heat transfer

Heat exchangers are used in AC and furnaces

Analysis of heat exchanger

For analy ing of heat exchanger we will discuss the two methods. !og "ean #emperature $ifference "ethod %!"#$& effectiveness' (#) method Heat exchangers usually operate for long periods of time with no change in there operating condition. #herefore* they can be modeled as study flow device.

Assumptions
#he mass flow rate of each fluid remain constant. #he fluid properties such as temp. and velocity at inlet and outlet remain same. #he fluid stream experienced little or no change in their velocities and elevations* and thus the kinetic and potential energy changes are negligible. #he specific heat of the fluid* in general* changes with temp. +ut* in a specified temperature range it can be treated as a constant at some average value with little loss in accuracy. Axial heat conduction along the tube is usually insignificant and can be considered negligible. Finally* the outer surface of the heat exchanger is assumed to be perfectly insulated.

)nder these assumptions* the first law of thermodynamucs requires that the rate of heat transfer from the hot fluid be equal to the rate of heat transfer to the cold one.That is,

,rinciple of heat exchanger

Counter flow

Parallel flow

C) C > ( m C) H (m

C) C < ( m C) H (m

!"#$ methods. #he curse of the non'linear behavior

Due to the nonlinear behavior of the temperature difference cross the heat exchanger. An appropriate average temperature difference has to be adopted

#he lmtd definition

#he correction factor F for multi'pass and cross'flow #he standard lmtd formulation is limited to the simple cases of parallel and counter flow configurations. In more complex cases as cross flow and multi'pass the correction factor F has to be considered.

SE ECT!"N "# HEAT EXCHANGERS

Heat exchangers are complicated devices and the result obtained with the simplified approach presented should be used with care.

It is natural to tend to overdesign the heat exchanger in order to avoid unpleasant surprises.

Engineers in industry often find themselves in a position to select heat exchangers to accompany certain heat transfer tas-s.

Heat transfer enhancement in heat exchanger is usually accompanied by increased pressure drop and thus higher pumping power. #herefore any gain from enhancement should be weighed at the cost of the accompanying pressure drop.

.ome thought should be given to which fluid should pass through the tube side and which through the shell side. )sually the more viscous fluid is suitable for shell side %larger passage area and thus lower pressure drop& and fluid with higher pressure for the tube side.

#HE ,/0,E/ .E!EC#I0( $E,E($. 0( F0!!01I(2 FAC#0/.3 HEA# #/A(.FE/ /A#E .I4E A($ 1EI2H# C0.# ,)",I(2 ,01E/ "A#E/IA!

HEAT TRANS#ER #he heat exchanger should be capable of transferring heat at the specified rate in order to achieve the desired temperature change of the fluid at the specified mass flow rate S!$E AN% &E!GHT (ormally the smaller and lighter heat exchanger is the better one. #his is especially in the case of automotive and aerospace industries. !arger heat exchangers carry higher price tag. #he space available for the heat exchanger in some cases limits the length of the tube that can be used.

C"ST +udgetary limitations plays an important role in the selection oh heat exchangers* except where money in not so important. An 0ff'the'shelf heat exchanger has a definite cost advantage over those made to order as in the cases where heat exchangers are integral part of the overall device to be manufactured. #he operating and maintenance costs of the heat exchanger are also important considerations in assessing the overall cost
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P'(P!NG P"&ER In heat exchangers* both fluids are usually forced to flow by pumps or fans that consume electrical power. ,umping power is the total electrical power consumed by the motors of the pumps and fans. (ATER!A S A temperature difference of 89oC or more between the tubes and the shell will probably pose differential thermal expansion problems and need to be considered. In case of corrosive fluids* we may have to select expensive corrosion resistance materials such as stainless steel.

#"' !NG #ACT"R

#he performance of heat exchanger usually deteriorates with time as a result of accumulation of deposits on heat transfer surfaces. #he layer of deposits represents additional resistance to heat transfer and causes the rate of heat transfer in a heat transfer to decrease. #he net effect of these accumulation of heat transfer is represented by fouling factor which is a measure of thermal resistance induced by fouling.

Fouling should be considered in the design and selection of heat exchanger. In such application it may be necessary to select a larger and expensive heat exchanger.

#he periodic cleaning of heat exchanger and the resulting down time are additional penalties associated with fouling.

#he fouling factor depends on operating temperature and the velocities of fluids and length of service. Fouling increases with increasing temperature and decreasing velocities.

Fouling Factor

,recipitation of solid deposits

Corrosion and Chemicals fouling

+iological fouling

PREC!P!TA!"N "# S" !% %EP"S!TES

#hese is specially found in the areas where the water is hard. #he scales of such deposits come off by scratching and the surfaces can be cleaned of such deposits by chemical treatment. #o avoid these problem* water in power and process plants is extensively heated and its solid contents are removed before it is allowed to circulates through the system. #he solid ash particles in the flue gases accumulating on the surfaces of air pre'heaters create similar problems.

CHE(!CA #"' !NG

In this case surfaces are fouled by the accumulation of the products of chemical reactions on the surfaces. #his form of fouling can be avoided by coating metal pipes with glass or using plastic pipe instead of metal ones.

)!" "G!CA #"' !NG

Heat exchangers may also be fouled by the growth of algae in warn water. #his type of fouling can be prevented by chemical treatment.

#he closed'type exchanger is the most popular one. 0ne example of this type is the $ouble pipe exchanger.

In this type* the hot and cold fluid streams do not come into direct contact with each other. #hey are separated by a tube wall or flat plate.

1hy shell'and'tube: CEC survey3 .;# accounted for <8= of new exchangers supplied to oil'refining* chemical* petrochemical and power companies in leading European countries. 1hy: Can be designed for almost any duty with a very wide range of temperatures and pressures Can be built in many materials "any suppliers /epair can be by non'specialists $esign methods and mechanical codes have been established from many years of experience

.cope of shell'and'tube
"aximum pressure > .hell ?99 bar %@899 psia& > #ube A@99 bar %B9999 psia& #emperature range > "aximum C99oC %AA99oF& or even C89oC > "inimum 'A99oC %'A89oF& Fluids > .ubDect to materials > Available in a wide range of materials .i e per unit A99 ' A9999 ftB %A9 ' A999 mB& Can *e exten+e+ with special +esigns,materials

Construction
+undle of tubes in large cylindrical shell +affles used both to support the tubes and to direct into multiple cross flow 2aps or clearances must be left between the baffle and the shell and between the tubes and the baffle to enable assembly .hell

#ubes +affle

.hell'side flow

#ube layouts

#riangula r ?9o

/otated triangula r C9o

pitch .Fuar e G9o

/otate d sFuare @8o

#ypically* A in tubes on a A.B8 in pitch or 9.E8 in tubes on a A in pitch #riangular layouts give more tubes in a given shell .Fuare layouts give cleaning lanes with close pitch

#E"A standards
#he design and construction is usually based on #E"A <th Edition AGG< .upplements pressure vessel codes li-e A."E and +. 8899 .ets out constructional details* recommended tube si es* allowable clearances* terminology etc. ,rovides basis for contracts #ends to be followed rigidly even when not strictly necessary "any users have their own additions to the standard which suppliers must follow

#E"A terminology
/ear end head type

Front end stationary head type

.hell

!etters given for the front end* shell and rear end types Exchanger given three letter designation Above is AE!

Front head type

A'type is standard for dirty tube side +'type for clean tube side duties. )se if possible since cheap and simple.

Channel and removable cover

+onnet %integral cover&

"ore front'end head types

C'type with removable shell for ha ardous tube'side fluids* heavy bundles or services that need freFuent shell'side cleaning ('type for fixed for ha ardous fluids on shell side $'type or welded to tube sheet bonnet for high pressure %over A89 bar&

.hell type
E'type shell should be used if possible but F shell gives pure counter'current flow with two tube passes %avoids very long exchangers&

E
0ne'pass shell

!ongitudinal baffle

Note- longitu+inal *affles are +ifficult to seal with the shell especially when reinserting the shell after maintenance

#wo'pass shell

"ore shell types

2 and H shells normally only used for hori ontal thermosyphon reboilers H and I shells if allowable pressure drop can not be achieved in an E shell

G
.plit flow

H
!ongitudinal baffles $ouble split flow

.
$ivided flow

X
Cross flow

/ear head type

#hese fall into three general types
fixed tube sheet %!* "* (& )'tube floating head %,* .* #* 1&

)se fixed tube sheet if T below 89oC* otherwise use other types to allow for differential thermal expansion 6ou can use bellows in shell to allow for expansion but these are special items which have pressure limitations %max. ?8 bar&

Fixed rear head types

Fixed tube sheet

! is a mirror of the A front end head " is a mirror of the bonnet %+& front end ( is the mirror of the ( front end

Floating heads and ) tube

Allow *un+le remo/al an+ mechanical cleaning on the shell si+e ) tube is simple design but it is difficult to clean the tube side round the bend

Floating heads
T S

,ull through floating head (ote large shell7bundle gap

.imilar to # but with smaller shell7 bundle gap

.plit bac-ing ring

0ther floating heads

(ot used often and then with small P exchangers &

0utside pac-ing to give smaller shell7bundle gap

Externally sealed floating tube sheet maximum of B tube passes

.hell'to'bundle clearance %on diameter&

A89 #

Clearance* mm

A99 , and . 89 Fixed and )'tube A.8 B.9 A.9 .hell diameter* m

9.8

B.8

Example
+E. +onnet front end* single shell pass and split bac-ing ring floating head

1hat is this:

Allocation of fluids
,ut dirty stream on the tube side ' easier to clean inside the tubes ,ut high pressure stream in the tubes to avoid thic-* expensive shell 1hen special materials reFuired for one stream* put that one in the tubes to avoid expensive shell Cross flow gives higher coefficients than in plane tubes* hence put fluid with lowest coefficient on the shell side If no obvious benefit* try streams both ways and see which gives best design

Example A
%e*utaniser o/erhea+ con+enser
Hot side Cold side

Fluid !ight hydrocarbon Cooling water Corrosive (o (o ,ressure%bar& @.G 8.9 #emp. In70ut %oC& @C 7 @B B97?9 Jap. fract. In70ut A79 979 Fouling res. %mBK71& 9.9999G 9.999A<

Example B
Cru+e tan0 outlet heater
Cold side Hot side Fluid Crude oil .team Corrosive (o (o ,ressure%bar& B.9 A9 #emp. In70ut %oC& A9 7 E8 A<9 7 A<9 Jap. fract. In70ut 9 7 9 A 7 9 Fouling res. %mBK71& 9.9998 9.999A

/ule of thumb on costing

,rice increases strongly with shell diameter7number of tubes because of shell thic-ness and tube7tube'sheet fixing ,rice increases little with tube length Hence* long thin exchangers are usually best Consider two exchangers with the same area3 fixed tubesheet* ?9 bar both side* carbon steel* area C9C9 ftB %8C@ mB&* ?7@ in %AG mm& tubes

!ength A9ft C9 in C9ft B8 in

$iameter #ubes ?A?G LAAB- %ME9-& 8B? L8@- %M?@-&

Cost

.hell thic-ness
t

Ds

p
t

p is the guage pressure in the shell t is the shell wall thic-ness is the stress in the shell
From a force balance

2t = pDs

hence

pDs t= 2

#ypical maximum exchanger si es

Floating Head
$iameter !ength Area C9 in %A8B@ mm& ?9 ft %G m& A? C89 ftB %ABE9 mB&

Fixed head ; ) tube

<9 in %B999 mm& @9 ft %AB m& @C @99 ftB %@?A9 mB&

Note that- to remo/e *un+le- you nee+ to allow at least as much length as the length of the *un+le

Fouling
.hell and tubes can handle fouling but it can be reduced by -eeping velocities sufficiently high to avoid deposits avoiding stagnant regions where dirt will collect avoiding hot spots where co-ing or scaling might occur avoiding cold spots where liFuids might free e or where corrosive products may condense for gases
High fouling resistances are a self'fulfilling prophecy

Flow'induced vibration
#wo types ' /E.0(A(CE and I(.#A+I!I#6 /esonance occurs when the natural freFuency coincides with a resonant freFuency Fluid elastic instability Both depend on span length and velocity
Resonance Instability

Tube displacement

Velocity

Velocity

Avoiding vibration
Inlet support baffles ' partial baffles in first few tube rows under the no les $ouble segmental baffles ' approximately halve cross flow velocity but also reduce heat transfer coefficients ,atent tube'support devices (o tubes in the window %with intermediate support baffles& H'.hell ' velocity is halved for same baffle spacing as an E shell but decreased heat transfer coefficients

Avoiding vibration %cont.&

Inlet support baffles 1indows with no tubes

$ouble'segmental baffles Intermediate baffles #ubes

(o tubes in the window ' with intermediate support baffles

.hell'side enhancement
)sually done with integral* low'fin tubes
> AA to @9 fpi %fins per inch&. High end for condensation > fin heights 9.< to A.8 mm

$esigned with o.d. %over the fin& to fit into the a standard shell'and'tube #he enhancement for single phase arises from the extra surface area %89 to B89= extra area& .pecial surfaces have been developed for boiling and condensation

!ow'finned #ubes
Flat end to go into tube sheet and intermediate flat portions for baffle locations

Available in variety of metals including stainless steel* titanium and inconels

#ube'side enhancement using inserts

.piral wound wire and twisted tape Increase tube side heat transfer coefficient but at the cost of larger pressure drop %although exchanger can be reconfigured to allow for higher pressure drop& In some circumstances* they can significantly reduce fouling. In others they may ma-e things worse Can be retrofitted
#wisted tape

 +oth mixes the core %radial mixing& and brea-s up the boundary layer Available in range of wire densities for different duties

1ire'wound inserts %Hi#/A(&

,roblems of Conventional . ; #
Zig ag path on shell side leads to ,oor use of shell'side pressure drop ,ossible vibration from cross flow $ead spots
> ,oor heat transfer > Allows fouling

/ecirculation ones
> ,oor thermal effectiveness*

Conventional .hell'side Flow

.ome problems can be overcome by having axial flow 2ood heat transfer per unit pressure drop but
> for a given duty may get very long thin units > problems in supporting the tube

.hell'side axial flow

/0$baffles %,hillips petroleum& introduced to avoid vibrations by providing additional support for the tubes also found other advantages
> low pressure drop > low fouling and easy to clean > high thermal effectiveness

/0$baffles
#end to be about A9= more expensive for the same shell diameter

#wisted tube %+rown Fintube&

#ubes support each other )sed for single phase and condensing duties in the power* chemical and pulp and paper industries

.hell'side helical flow %A++ !ummus&

Independently developed by two groups in (orway and C ech /epublic

Comparison of shell side geometries

Twisted tube Y N Y Y Included Y Y Segmental Helical ROD baffles baffles baffles N Y Y Y Y N N Y Y With square With square Y pitch pitch With inserts With inserts With inserts N N Y Y

Good / p High shell ow fouling !as" cleaning Tube#side enhance. $an give high ow vibration

With special With double designs helix