HEAT EXCHANGERS

HEAT EXCHANGERS
 Introduction

➢ A heat exchanger - device in which two fluid streams,

hot and cold, are brought into ‘thermal contact’ to effect
transfer of heat.

➢ Large area of heat transfer for a given volume.

➢ The driving force is ∆T.

What are heat exchangers for ?

❑ To get hot fluid streams for the next process

❑ To condense vapours
❑ To evaporate liquids
❑ To recover heat
Classification of Heat Exchangers

1) Operations

2) Flow Basis of 4)Construction

arrangement classification

3) Function
 Classification of HE’s…….
1) Based on operation.
1) Recuperative type: Ex- Boilers
Condensers
Evaporators

2) Regenerative type: Ex- Open hearth furnace

Glass melting furnace

3) Mixed type: Ex- Spray tower

Cooling tower
 Recuperators/Regenerators

❑ Recuperative:
Has separate flow paths for each
fluid which flow simultaneously
through the exchanger transferring
heat between the streams
❑ Regenerative
Has a single flow path which the
hot and cold fluids alternately pass
through.
2) Based on flow pattern:
1) Co-current/Parallel flow
2) Counter current/Counter flow
3) Cross flow

3) Based on the function:

1) Heater.
2) Coolers
3) Condensers
4) Evaporators
5) Vaporizers
4) Based on the construction
1) Double pipe heat exchanger (DPHE)
2) Spiral type heat exchanger
3) Cross Flow heat exchanger
4) Plate type heat exchanger(PHE)
5) Shell and Tube heat exchanger (STHE)
1. Double Pipe Heat Exchanger
(DPHE)
❑Several hairpins may be connected in series to obtain
large heat transfer area.
❑All the return bends of the inner pipe are kept outside
the jacket and do not contribute to the heat transfer area.
 Components
❖ Packing & gland
The packing and gland provides sealing to the annulus and
support the inner pipe.
❖ Return bend
The opposite ends are joined by a U-bend through welded joints.
❖ Support lugs
Support lugs may be fitted at these ends to hold the inner pipe
position.
❖ Flange
The outer pipes are joined by flanges at the return ends in order
that the assembly may be opened or dismantled for cleaning and
maintenance.
❖ Union joint
For joining the inner tube with U-bend.
 Double pipe heat exchanger

➢ Simple to construct.
➢ Consists of a pipe fixed concentrically inside a larger pipe.
➢ Used for small heat duty are small (less than 500 kW).
➢ More space.
➢ Carbon Steels,
Low Alloy Steels,
High Alloy Stainless Steels.
 Co-current flow Counter-current flow
(Fluids flow in same direction) (Fluids flow in opposite direction)
Advantages of DPHE
• Good efficiency with lower capital costs.
• Small heat transfer area compared to the STHE.
• Parts have been standardized and flexible design, repair and
maintenance very easy (straight tube design).
• Can be used at high pressure and temperature.
• The design of the exchanger allows more thermal expansion
without any expansion joint.

Disadvantages of DPHE
• They are usually used in counterflow designs.
• Used in low heat duties.
• Leaking is more often.
2. Spiral Type Heat Exchanger
3. Cross Flow Heat Exchanger
4. Plate Type Heat Exchanger
A plate type heat exchanger is a type of heat exchanger that
uses metal plates to transfer heat between two fluids.
major advantage over a conventional heat exchanger in
that the fluids are exposed to a much larger surface area
because the fluids spread out over the plates.
Shell & Tube Heat Exchanger
(STHE)
 Working Principle of Shell and Tube Heat Exchanger

The shell and tube exchanger consists of four major parts:

Front Header—this is where the fluid enters the tubeside of the exchanger. It is
sometimes referred to as the Stationary Header.
Rear Header—this is where the tubeside fluid leaves the exchanger or where it is
returned to the front header in exchangers with multiple tubeside passes.
Tube bundle—this comprises of the tubes, tube sheets, baffles and tie rods etc. to hold
the bundle together.
Shell—this contains the tube bundle.
The remainder of this section concentrates on exchangers that are covered by the
TEMA Standard.
The shell
❑The shell is the enclosure and passage of the shell-side
fluid.
❑It has a circular cross-section.
❑The selection of the material depends upon the
corrosiveness of the fluid and the working temperature
and pressure.
❑Carbon steel is a common material for the shell under
moderate working conditions.
The tubes
❑The tubes provide the heat transfer area in a shell and tube
heat exchanger.
❑Tubes of 19mm and 25mm diameter are more commonly
used.
❑The tube wall thickness is designated in terms of BWG
(Birmingham wire gauge).
❑Tubes are generally arranged in a triangular or square
pitch.
The bonnet and the channel
❑The closure of heat exchanger is called bonnet or channel
depending upon its shape and construction.
❑A bonnet has an integral cover and a channel closure has a
removable cover.
❑The bonnet closure consists of a short cylindrical section with
a bonnet welded at one end and a flange welded at the other
end.
❑The bonnet-type closure is replaced by a channel-type
closure if a nozzle is required to be fitted.
The pass partition plate
❑The channel is divided into compartments by a pass partition
plate.
❑The number of tube and shell-side passes can be increased
by using more pass partition plates for both the sides.
❑The number of passes in either the shell or the tube side
indicates the number of times the shell or the tube side fluid
traverses the
What is the purpose of baffles in a heat exchanger?

➢ To improve heat transfer efficiency, by creating

turbulence.
➢ Enhances the contact time between the fluids and
promotes efficient heat transfer.
➢ Prevent channeling of fluids.
➢ Control fluid velocity.
➢ Uniform fluid flow .
➢ To support tube bundle against sagging.
 Types of baffles

• Longitudinal Flow Baffles

• Impingement Baffles
• Single segmental.
• Double segmental.
• Triple segmental.
• Disk and doughnut.
Baffles
Baffles
 Tube layout inside Shell & Tube Heat exchanger

The tube layout should be selected based on parameters such as heat transfer,
pressure drop and fouling
 Tube Pitch

Pt = 1.25 do
Rods and spacers
Shell and Tube heat exchanger types based on construction

1. Fixed Tube Sheet Heat Exchanger

2.Floating Head Heat Exchanger
3. U-tube Heat exchanger
The U-tubes permit unlimited thermal expansion, the tube bundle can be removed
for cleaning and small bundle to shell clearances can be achieved. However, since
internal cleaning of the tubes by mechanical means is difficult, it is normal only to
use this type where the tube side fluids are clean.
Mostly used in higher-pressure and Higher Temperature applications.
1. FIXED TUBE SHEET - This is the simplest form of exchanger , but has
limitations:
a. Temperature limit of 65C between the two fluids as there is no provision for
expansion .
b. Refiner cannot clean shell side . Limits the shell side fluid to a clean surface .

2. FLOATING HEAD - To allow for tubes to expand due to the temperature

difference in a heat exchanger , one tube sheet moves inside the shell .
This floating head sheet must be enclosed by a floating head cover within the
shell to return the tube side fluid to the channel end . Most heat exchangers are
of this type .

3. U - TUBE - The tubes are one piece and made for a particular exchanger . The
tubes can expand and contract and only on tube sheet is required .
The bundle may be pulled for inspection , and cleaning the shell , but the tubes
may only be cleaned with the use of chemicals .
Most common use is in reboiler s where steam is condensed in the tubes .
❑ Shell diameters of 10 inches to more than 100

❑ 0.625” to 1.5" tubing

❑ made from low carbon steel, copper, copper-

nickel, stainless steel, Hastelloy, Inconel, or
titanium to resist corrosion.
 Advantages of STHE
✓ Compact design.
✓ Most versatile type.
✓ Large heat transfer surface in a small space.
✓Good mechanical layout.
✓ Can operate at wide temperature and pressure range.
✓ Easy in construction and maintenance.
✓ Made of a wide variety of materials.
✓ Well established design procedure.
✓ As the numbers of tubes are more in a shell and tube HE, we can
expect a higher turbulence which will result in higher heat
transfer rates.

✓ Dirty fluids also can be handled owing to easy cleaning.

Components of STHE …..
1:1 1:2

1:4
1:4 Floating Head STHE
2:2 Shell and Tube HE ?
 Design of
tubular HEAT EXCHANGERS

Q = UA ∆T
Design codes and standards for
tubular HEAT EXCHANGERS
 Three industrial standards &
one code
➢ TEMA
(Tubular Exchanger Manufacturer’s Association)

➢ API Standards 660

(American Petroleum Institute)

➢ HEI
(Heat Exchange Institute)

➢ ASME; Boiler and Pressure Vessel Code

(American Society of Mechanical Engineers)
Three equipment classes within TEMA

• Class R Exchangers – Refinery and Petrochemical

(costly; corrosion resistance)

• Class C Exchangers – Commercial application

• Class B Exchangers- Chemical Process

 TEMA Designation
Standard nomenclature: three letters & diagrams

First letter front header type

Second letter shell type

Third letter rear header type.

Examples of a BEM, CFU, and AES exchangers

Front Head Type

A-Type B-Type C-Type

Shell type

E-Type F-Type

J-Type K-Type
Rear End Head Types

M-Type S-Type T-Type

Fixed Tubesheet Floating Head Pull-Through
Floating Head
Fouling
 Deposition of any undesired material on heat transfer surfaces is called fouling

The deposition of any undesired material on heat transfer surfaces is called

fouling. Fouling may significantly impact the thermal and mechanical
performance of heat exchangers.

Fouling is a dynamic phenomenon which changes with time.

Fouling increases the overall thermal resistance and lowers the overall heat
transfer coefficient of heat exchangers. Fouling also impedes fluid flow,
accelerates corrosion and increases pressure drop across heat exchangers.
Types of fouling
•Fouling and Sedimentation can have the following reasons

•Precipitation fouling: Precipitation and deposition of salts. Example:

Best example for this behaviour is heating of water at temperature above
45°C to 55°C carbonates crystallize and will build up a film on the heat
transfer area.

•Particle fouling: Sedimentation of sand or mud on surfaces with any

kind of slope.

•Reaction fouling: Formation of deposits caused by chemical reactions on

the heat transfer surface. Example: Heating protein containing products
like milk will lead at certain temperatures to a burning of these proteins on
the hot surface.

•Corrosion fouling: Formation of an oxide layer on the on the heating

surface.The thermal transfer resistance is very low, because the oxide
surfaces are very thin and the heat conductivity is relative high. The
problem of the corrosion fouling is the supporting trait of other kinds of
fouling.

•Biological fouling: Increase of algae, mussels, bacteria or others on the

heat transfer surface. Example: Mostly related when river or sea water is
used as cooling water.
 Affects of Fouling

1.Increased capital cost. More heat transfer area has to

be provided to account for fouling.

2.Higher pumping cost due large pressure drop.

3.Lower heat duty (low K value).

4.Higher maintenance cost due to frequent cleaning.

5. Production loss due to shutdown.

Anti-fouling is the process of removing or
preventing these accumulations from
forming.

Methods :

A) Mechanical
1) Brush (rotary)
2) Scraper
3) Sonic resonance
4) Hydroblasting
5) Ultrasonic cleaning

B) Chemical
1)Chlorination (remove carbonate deposit)
1) Brush (rotary)
2) Scraper
3) Sonic resonance
4) Hydroblasting
5) Ultrasonic cleaning
 Fouling Resistance (Rd)
▪Deposition of any undesired material on heat transfer surfaces is
called fouling, and the heat transfer resistance offered by the deposit is
called the fouling factor or dirt factor, commonly denoted by Rd.

▪Fouling increases the overall thermal resistance and lowers the

overall heat transfer coefficient of heat exchangers.

▪The fouling factor is zero for a new heat exchanger.

▪It can be only be determined from experimental data on heat transfer

coefficient of a fouled exchanger and a clean exchanger of similar
design operated at identical conditions.
Typical values for fouling factor coefficients
Temperature profile in
Heat Exchangers
Q = U A ΔtAm

Q = U A Δtln
➢ LMTD is used to determine the temperature
driving force for heat transfer in flow systems,
most notably in heat exchangers.

➢ log mean temperature difference (LMTD)

➢ The LMTD is a logarithmic average of the

temperature difference between the hot and
cold streams at each end of the exchanger.

➢ The larger the LMTD, the more heat is

transferred.
For counter current

For co-current
Correction factor in STHE
& Cross flow HE

Q= U A ▲T ln
 Correction factor

Corrected
LMTD