A

Presentation
on
HEAT
EXCHANGE
R DESIGN
BY:
A.KUMAR
3rd year
 WHAT ARE HEAT
EXCHANGERS?

Heat exchangers are one of the most common pieces of

equipment found in all plants.
Heat Exchangers are components that allow the transfer
of heat from one fluid (liquid or gas) to another fluid.
In a heat exchanger there is no direct contact between
the two fluids. The heat is transferred from the hot fluid to
the metal isolating the two fluids and then to the cooler
fluid.
 APPLICATION OF HEAT
EXCHANGERS

Heat exchange is used every where around the human and

its surroundings.

Heat exchangers are used in many industries, some of

which include:
Waste water treatment,
Refrigeration systems,
Wine-brewery industry,
Petroleum industry,
 CLASSIFICATION OF HEAT
EXCHANGER

Basic Classification
Regenerative Type
Recuperative Type

Classification Based On Fluid Flow

Liquid/Liquid
Liquid/Gas
Gas/Gas
 Classification by flow arrangements

Concurrent Flow in same direction

Thermodynamically poor
High thermal stresses since large
temperature difference at inlet

Counter current- flow opposite to each other

Thermodynamically superior
Minimum thermal stresses
Maximum heat recovery
Least heat transfer area

Cross flow- Flow perpendicular to each other

In between the above
Space is important
 TUBULAR HEAT EXCHANGER

This type of heat exchanger are categorized in following types:-

Double Pipes heat Exchanger

Shell & Tube Heat Exchanger
Spiral Tube Heat Exchanger
 DOUBLE-PIPE HEAT
EXCHANGER

Simplest type has one tube inside another - inner tube

may have longitudinal fins on the outside
 SHELL AND TUBE HEAT
EXCHANGER

Shell and tube heat exchangers consist of a series of tubes. One set of these tubes
contains the fluid that must be either heated or cooled. The second fluid runs over
the tubes that are being heated or cooled so that it can either provide the heat or
absorb the heat required.

A set of tubes is called the tube bundle and can be made up of several types of
tubes: plain, longitudinally finned.
PLATE HEAT EXCHANGER
This type of heat exchanger are categorized in following types:-

Plate & Frame Heat Exchanger

Spiral Heat Exchanger

 PLATE & FRAME HEAT
EXCHANGER

A plate type heat exchanger consists of plates instead of tubes to separate the hot
and cold fluids.

The hot and cold fluids alternate between each of the plates. Baffles direct the flow
of fluid between plates.

Because each of the plates has a very large surface area, the plates provide each of
the fluids with an extremely large heat transfer area.

Therefore a plate type heat exchanger, as compared to a similarly sized tube and shell
heat exchanger, is capable of transferring much more heat.

This is due to the larger area the plates provide over tubes.
 SELECTION OF HEAT
EXCHANGERS
Terminal Temperatures
Types of Fluids
Properties of Both Fluids
Flow Arrangement
Operating Pressure and Temperature
Pressure Drop
Heat Recovery
Fouling
Ease of Inspection, Cleaning, Repair & Maintenance
Materials of Construction
Cost of Heat Exchanger
 Terminal Temperatures

Performance of Heat Exchanger depends on

terminal temperatures

Heat Transfer Units (HTU) defined as ratio of

* Temperature of one fluid
* Mean temperature difference between the fluids

Plate heat exchanger > Tubular Heat Exchanger

Up to 4 HTU in case of Plate heat exchanger
 Properties of Both Fluids
Heat Transfer Calculations
Pumping Calculations

Viscosity
Low viscosity- Plate heat exchanger
High viscosity- Scraped surface heat exchanger
Thermal conductivity
Density
Specific heat
Thermal diffusivity
Operating Pressure and Temperature
Mechanical Design
Operating Pressure
Operating Temperature

Problems of high operating temperature and pressure

Vibration
Fatigue
Thermal stresses, etc.

Plate heat exchanger free from such problems however plate

thickness and gasket material limit its application
Heat Exchanger T, 0C P, N/cm Q, l/h
Plate heat exchanger 260 21 50,00,00
Double pipe 540 70 no limit
Shell and tube 540105 no limit
 Pressure Drop
Important for
Pumping Cost - proportional to pressure drop
Heat Transfer Rate - proportional to pressure drop
Heat Recovery

Conservation of energy- very important

Recovery of heat from used/waste process streams

Less than 50% in tubular heat exchangers

Up to 95% in plate heat exchanger
 Fouling
Deposition of solid material- poor conductor of heat
* Decreases heat transfer
* Decreases flow rate
* Lead to corrosion
* Loss of valuable materials
* Affects the design and size of the unit
* Affects the production runs

Factors affecting fouling

Velocity- High velocity less fouling
* Shearing force * Turbulence
* Laminar layer thickness * Residence time
Surface temperature important for heat sensitive liquids
- small temperature difference required
Bulk fluid temperature more fouling in less bulk temperature
Composition
 Materials of Construction
Material of construction depends on
Properties of the fluids such as heat sensitivity, fouling,
corrosivity,
Operating temperature and pressure
Welding ease
Availability
Conformance to all applicable laws, codes and
insurance requirements
Cost
Materials
Stainless steel Carbon steel Graphite
Aluminum Titanium Hastalloy
Gaskets
Nitryl rubber Butyl rubber
Teflon Compressed asbestos fibers
 Overall Heat Transfer Coefficient
An essential requirement for heat exchanger design or performance calculations.

Contributing factors include convection and conduction associated with the

two fluids and the intermediate solid, as well as the potential use of fins on both
sides and the effects of time-dependent surface fouling.

With subscripts c and h used to designate the hot and cold fluids, respectively,
the most general expression for the overall coefficient is:

1 1 1
UA UAc UA h

1 Rf , c Rf , h 1
Rw
o hAc o Ac o Ah o hAh