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Heat Exchanger Testing

Thermal Heat Exchanger
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Some heat exchangers
use tubular baffles to
radiate heat.
Traditional hot water
radiators are a type of
heat exchanger.
A heat exchanger is a specialized device that assists in the
transfer of heat from one fluid to the other. In some cases, a solid
wall may separate the fluids and prevent them from mixing. In other
designs, the fluids may be in direct contact with each other. In the
most efficient heat exchangers, the surface area of the wall
between the fluids is maximized while simultaneously minimizing
the fluid flow resistance. Fins or corrugations are sometimes used
with the wall in order to increase the surface area and to induce
turbulence.
Common appliances containing a heat exchanger include air
conditioners, refrigerators, and space heaters. These devices are
also used in chemical processing and power production. Perhaps
the most commonly known heat exchanger is a car radiator, which
cools the hot radiator fluid by taking advantage of airflow over the
surface of the radiator.
There are three primary flow arrangements with heat exchangers:
counter-flow, parallel-flow, and cross-flow. In the counter-flow
exchanger, the fluids enter the exchanger from opposite sides.
This is the most efficient design because it transfers the greatest
amount of heat. In the parallel-flow version, the fluids come in from
the same end and move parallel to each other as they flow to the
other side. The cross-flow heat exchanger moves the fluids in a
perpendicular fashion.
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There are also four different designs of heat exchangers: shell and
tube, plate, regenerative, and intermediate fluid or solid. The most
typical type is the shell and tube design. This has multiple finned
tubes. One of the fluids runs through the tubes while the other fluid
runs over them, causing it to be heated or cooled. In the plate heat
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A refrigerator contains a
heat exchanger.
exchanger, the fluid flows through baffles. This causes the fluids to
be separated by plates with a large surface area. This type of
exchanger is typically more efficient than the shell and tube
design.
The regenerative heat exchanger takes advantage of the heat
from a specific process in order to heat the fluid used in the same
process. These can be made with the shell and tube design or the
plate design. The intermediate fluid or solid heat exchanger uses
the fluids or solids within it to hold heat and move it to the other
side in order to be released. This method is commonly used to
cool gases while removing impurities at the same time.
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can we design a rectangular detachable shell
instead cylindrical shell which will enable cleaning
of tubes to avoid fouling? what precautions to
take in avoiding shell flange leaks?
Brazed heat exchangers employ an alloy of
copper and zinc in a square design which is
becoming a commonplace type of heat exchanger.
This kind is likely to foul at a slower rate and is
more effective than the older types.
Heat exchanger fouling is a problem which needs
to be fixed regularly when the heat exchanger
rusts or has excessive sediment to the point
where it is rendered ineffective. The costs for this
can be very high in highly industrialized countries.
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