Heat Exchangers

Prepared by Osama Hasan GTE Amm 3 Engro Fertilizers 1

Outline
Working

Principle and Types Construction Baffles Types and Definitions Operational Problems

Heat Exchanger Heat Transfer Through Tubes Temperature Profile Flow Profile: Parallel Flow Profile: Counter Effective Heat Transfer Surface Types of Heat Exchanger

Heat Exchanger
An equipment in which heat is exchanged between two process streams. The heat picked up by the cold stream saves fuel, and heat removed from hot stream saves cooling water; Achievements: Less fuel consumption Smaller cooling tower units Shell and tube heat exchanger consists of a number of tunes enclosed inside a close-fitting shell

Heat Transfer

Modes
Conduction
Travels through a solid until heat is equally distributed with a rate function of temperature difference Mixing of one part of fluid with another

Convection

Energy transfer via light in the absence of transfer media

Radiation

Through Tubes

Heat transfer depends upon the type of fluid flow

Static Film follows slow conduction Mainstream follows convection

Transfer rate: Turbulent > Laminar

Turbulence dictates heat transfer rate by decreasing the thickness of static film Turbulent flow has less static film thickness Fluids are poor conductors of heat

Temperature Profile

T2 T3 Static Fluid Film (in) T3 T4 Fouling (Inside) T4 T5 Tube Material T5 T6 Fouling (Outside) T6 T7 Static Fluid Film (out)

Tube Material Straight Static Fluid Film Steep Fouling - Steeper

Flow Profiles: Parallel

Since Heat transfer occurs due to Temperature gradient, the temperature difference is reduced across the flow line and the hot fluid cannot be cooled below the highest temperature of the cooler fluid

Flow Profiles: Counter

Temperature difference is remains across the flow line and the hot fluid is cooled below the highest temperature of the cooler fluid

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Effective Heat Transfer Surface

Effective heat transfer depends upon:

Number of Tubes Length of tubes Outside diameter of tubes Effective Surface:

Effective Length is less than actual length

External surface per foot length x Net effective tube length x Number of tube

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Types of Heat Exchanger

Disk Type Rotary Regenerators Fixed Matrix Drum Type

Fixed Tube Shell-andTube

U-Tube
Heat Exchanger Tubular Double-Pipe

Spiral Tube

Gaskette Indirect Contact

Parallel Flow Counter Cross Flow

Recuperators
Direct Contact

Plate

Spiral

Lamella

Mixed
Plate fin

Unmixed

Extended Tube Fin

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SnT Heat Exchanger Tube Bundle Tube Sheet Tube Joints Tube Layouts

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SnT Heat Exchanger

Shell side:

Area inside the shell and outside the tube Area inside the tube The metal plates between which tubes are anchored

Tube side:

Tube sheet:

Bundle:

Combination of tubes and tube sheets

Heat can be transferred from tube to shell or vice versa.

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Tube Bundle

Greater the surface area of conductor, more quickly heat is conducted Area Bundle of small tubes > Area Single large tube Fins increase the surface area and the heat transfer

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Tube Sheet

Tube sheets and tubes form a single solid unit which is often prevented from moving On thermal expansion creates stress resulting in leak b/w tube wall and opening in the tube sheet Double tube sheets are used to guard against this. The design space between the tube sheets helps reduce the leakage possibility.

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Tube Joints
Connection b/w the tube and the tube sheet Rolled Press joints make better seal and give high pressure service up to 2000 psi Welded joints are better for special cases or severe service. Welded joints more costly.

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Tube Layout
Clearance Shortest distance between two adjacent tube holes Pitch Shortest center-to-center distance between adjacent tubes. Pitch arrangements depend upon the acceptable pressure drop against a desired heat transfer In line square most efficient due to least pressure drop but small number of tubes in a given area Staggered Allow more tubes in given area therefore more heat transfer rate

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Baffles Segmental Disc and Doughnuts Impingement Longitudinal

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Baffles

Metal plates installed in exchanger shell

Support the weight of tubes helping relives the stress on tubing and tube sheets while Increase the turbulence Increase flow velocity Increase heat transfer rate

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Baffles: Segmental

Baffles with cut-out areas on alternate faces

Cause flow cross the tubes time and again Service with suspended particles use vertically cut baffles

Condensers avoid using horizontal baffles since they restrict drainage

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Baffles: Disc and Doughnuts

Offer uniform flow pattern Used less often

Sediments may buildup behind doughnuts Flow of condensed fluids along the bottom can be restricted

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Baffles: Impingement

Spreads out the fluid flow

Reduce tube erosion due to high inlet-fluid velocities Increases heat transfer

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Baffles: Longitudinal

Split shell side flow into two or more passes

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Size and Type Type Designation Flow Arrangements: Shell Flow Arrangements: Tube Fixed Tube sheet U-tube U-bend Floating Head Pull Through Type Split Backing Ring Type Service Functions Flow Path

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Size and Type

Acc. to TEMA, Exchanger size depends upon diameter of shell and length of tubes i.e. 23 - 192 means 23 inch shell dia and 192 inch tube length Type designation includes: Type of stationary head (A, B, C, D) Shell type (E, F, G, H, J, K) Type of rear head (L, M, N, P, S, T, U Exchangers are designated as Size17-192 Type CEN

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Type Designation

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Flow Arrangements: Shell

One

Pass Two Pass Split Flow Double Split Flow Divided Flow Kettle T

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Flow Arrangements: Shell

single pass shell-tube exchanger

double pass shell-tube exchanger

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Flow Arrangements: Tube

Tube side flow pass can be increased by increasing channel head baffle and floating head baffles .
Length of fluid flow path is increased without increase in exchanger length Greater heat transfer due to higher velocities than single pass

Multi-pass Advantages:

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STE: Fixed Tube sheet

Tube bundle is permanently installed with tube sheets welded in to the shell thus preventing expansion Built in expansion joints allow the shell expansion and lessened the stress of welding Difficult to inspect and clean Used in:

Limited temperature range Limited shell side fouling Chemical cleaning of shell side

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STE: U-tube/U-bend

Allows expansion of tubes similar to bends in pipes Due to difficult tube cleaning, it is used in service where tube side fluid is clean

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STE: Floating Head

Pull Through Type:

Tube sheet is fixed at one end only Horizontal movement is allowed but vertical movement is restricted by the weight of the tube bundle Tube bundle and floating head are a single unit Clearance b/w shell and tubes wastes heat transfer area

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STE: Floating Head

Split Backing Ring Type

More efficient exchanger The clearance between the tube bundle and the shell is smaller More tubes can be accommodated Expensive to built due to more parts Difficult to disassemble

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Service Functions
Chiller

Cools a fluid to a temperature below that obtainable if water only were used as a coolant. It uses a refrigerant such as ammonia or Freon. Condenses a vapor or mixture of vapors, either alone or in the presence of a non- condensable gas. Condenses vapors at a point high enough to provide a temperature difference sufficient to preheat a cold stream of process fluid. This saves heat and eliminates the need for providing a separate pre-heater (using flame or steam).

Condenser

Partial condenser

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Service Functions
Final condenser

Condenses the vapors to a final storage temperature of approximately 37.8C (100F). It uses water cooling, which means that the transferred heat is lost to the process. Cools liquids or gases by means of water. Exchanger Performs a double function: (1) heats a cold fluid by (2) using a hot fluid which it cools. None of the transferred heat is lost. Imparts sensible heat to a liquid or a gas by means of condensing steam or Dowtherm.

Cooler

Heater

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Service Functions
Re-boiler

Connected to the bottom of a fractionating tower, it provides the reboil heat necessary for distillation. The heating medium may be either steam or a hot-process fluid.

Thermosiphon Re-boiler
Natural circulation of the boiling medium is obtained by maintaining sufficient liquid head to provide for circulation. Forced-Circulation Re-boiler A pump is used to force liquid through the reboiler.

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Service Functions
Steam Generator

Generates steam for use elsewhere in the plant by using the available high-level heat in tar or a heavy oil.

Super-Heater

Heats a vapor above the saturation temperature.

A heater which vaporizes part of the liquid.

Vaporizer

Waste-Heat Boiler

Produces steam; similar to steam generator, except that the heating medium is a hot gas or liquid produced in a chemical reaction.

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Flow Path
Tube side fluid: Corrosive Dirtier Higher pressure Shell-side fluid High viscosity liquid Gas

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Startup / Shutdown

Before introducing any hydrocarbon into an exchanger, it must be purged with an inert gas or steam Shell and tube bundle are made of different metals to allow expansions at different rates Temperature changes must be slowly made to avoid any stress resulting in loosened or ruptures tubes Cooling fluid is introduced first, followed by hot fluid To avoid fluid expansion resulting stress on structure, exchanger should not be valved closed when its full and drained first

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Fouling
Build up of different kinds of deposits on the parts of an exchanger Consequences: Reduced heat transfer Increase in heat transfer time Restricted flow of fluids through exchanger General decrease in efficiency Increase in pressure drop

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Fouling
Types: Sedimentation: deposit of dirt, clay and dust Corrosion Products: formed due to interaction of exchanger material with the fluids Organic Material growth: algae growing in the cooling water Others: Coking, salt deposits, chemical reaction Supporters

Surface roughness Higher corrosion rates Lower fluid velocities

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Maintenance
Online

e.g. chemical Off-line e.g. mechanical, hydroblasting

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Testing for Leaks

Sampling from lower pressure fluid Hydrostatic test: water under pressure service Leaking tube can be plugged at both ends with a tapered plug or rerolled or welded back into the tube sheet Normal test pressure: 1.5 times designed pressure

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Thank you
Prepared by Osama Hasan Graduate Trainee Engineer Ammonia III Plant II Engro Fertilizers osama_hasan@hotmail.com