Heat Exchanger

PAMANTASAN NG LUNGSOD NG MAYNILA
University of the City of Manila

College of Engineering and Technology
Introduction to HEAT EXCHANGERS
Heat exchangers are devices used to transfer heat energy from one fluid to
another. Typical heat exchangers experienced by us in our daily lives include
condensers and evaporators used in air conditioning units and refrigerators. Boilers and
condensers in thermal power plants are examples of large industrial heat exchangers.
There are heat exchangers in our automobiles in the form of radiators and oil coolers. In
other applications, the objective may be to recover or reject heat, or sterilize,
pasteurize, fractionate, distill, concentrate, crystallize, or control a process fluid. Heat
exchangers are abundant in chemical and process industries.
Although heat flows from hot fluid to cold fluid by thermal conduction through
the separating wall (except in direct-contact types), heat exchangers are basically
heat convection equipment, since it is the convective transfer what governs its
performance. Convection within a heat exchanger is always forced, and may be with
or without phase change of one or both fluids.
There is a wide variety of heat exchangers for diverse kinds of uses, hence the
construction also would differ widely. However, in spite of the variety, most heat
exchangers can be classified into some common types based on some fundamental
design concepts.
Heat Exchanger |

In a few heat exchangers, the fluids exchanging heat are in direct contact. In
most heat exchangers, heat transfer between fluids takes place through a separating
wall or into and out of a wall in a transient manner. In many heat exchangers, the fluids
are separated by a heat transfer surface, and ideally they do not mix or leak. Such
exchangers are referred to as direct transfer type, or simply recuperators. In contrast,
exchangers in which there is intermittent heat exchange between the hot and cold
fluidsvia thermal energy storage and release through the exchanger surface or
matrix are referred to as indirect transfer type, or simply regenerators. Here, heat from
the hot fluid is intermittently stored in a thermal storage medium before it is transferred
to the cold fluid. To accomplish this, the hot fluid is brought into contact with the heat
storage medium, then the fluid is displaced with the cold fluid, which absorbs the heat.
Such exchangers usually have fluid leakage from one fluid stream to the other, due to
pressure differences and matrix rotation/valve switching.
Fouling
Material deposits on the surfaces of the heat exchanger tubes may add more
thermal resistances to heat transfer. Such deposits, which are detrimental to the heat
exchange process, are known as fouling. Fouling can be caused by a variety of reasons
and may significantly affect heat exchanger performance.
Fouling can be caused by the following sources:
Scaling is the most common form of fouling and is associated with inverse
solubility salts. Examples of such salts are CaCO3, CaSO4, Ca3(PO4)2, CaSiO3,
Ca(OH)2, Mg(OH)2, MgSiO3, Na2SO4, LiSO4, and Li2CO3.
Corrosion fouling is caused by chemical reaction of some fluid constituents with
the heat exchanger tube material.
Chemical reaction fouling involves chemical reactions in the process stream
which results in deposition of material on the heat exchanger tubes. This
commonly occurs in food processing industries.
Freezing fouling is occurs when a portion of the hot stream is cooled to near the
freezing point for one of its components. This commonly occurs in refineries
where paraffin frequently solidifies from petroleum products at various stages in
the refining process. , obstructing both flow and heat transfer.
Heat Exchanger |

Biological fouling is common where untreated water from natural resources such
as rivers and lakes is used as a coolant. Biological micro-organisms such as algae
or other microbes can grow inside the heat exchanger and hinder heat transfer.
Particulate fouling results from the presence of microscale sized particles in
solution. When such particles accumulate on a heat exchanger surface they
sometimes fuse and harden. Like scale these deposits are difficult to remove.
Basic Heat Exchanger Flow Arrangements

Counter-Flow
In
a
counter
flow
arrangement, the two streams enter
at opposite ends of the heat
exchanger and flow in parallel but
opposite directions.
This exchanger design is most
efficient when comparing heat
transfer rate per unit area. The
efficiency of a counter flow heat
exchanger is due to the fact that the average temperature (difference temperature)
between the two fluids over the length of the heat exchanger is maximized. Therefore,
the log mean temperature for a counter flow heat
exchanger is larger than that of parallel and cross
flow heat exchanger. And since it has a high log
mean temperature, then it means that it requires
smallest required heat exchanger area. This would
normally be expected to result in smaller, less
expensive equipment for a given application.
Counter flow is more appropriate for
maximum energy recovery. In a number of industrial applications there will be
considerable energy available within a hot waste steam which may be recovered
before the steam is discharged. This is done by recovering energy into a fresh cold
stream.
Heat Exchanger |

Parallel Flow
In parallel flow both the hot and cold
streams enter the heat exchanger at the same
end and travel to the opposite end in parallel
streams. Parallel flow results in rapid initial rates
of heat exchange near the entrance, but heat
transfer rates rapidly decrease as the
temperatures of the two streams approach
one another. This leads to higher exergy loss
during heat exchange. Exergy is the maximum
useful work possible during a process that brings the system into equilibrium.
In heating very viscous fluids, parallel
flow provides for rapid initial heating and
consequent decrease in fluid viscosity and
reduction in pumping requirement. In
applications where moderation of tube wall
temperatures is required, parallel flow results
in cooler walls. This is especially beneficial in
cases where the tubes are sensitive to
fouling effects which are aggravated by
high temperature.
Cross-Flow
Crossflow heat exchangers are intermediate in
efficiency between countercurrent flow and
parallel flow exchangers. In these units, the
streams flow at right angles to each other. Cross
Flow Heat Exchangers are one of the most
common types of heat exchanger used in
countless applications such as engine radiators,
air heaters, refrigeration evaporators and
condensers, super-heaters and economisers.
Heat Exchanger |

PLATE AND FRAME HEAT EXCHANGER (PHE)
A plate heat exchanger (PHE) is a heat exchanger that uses multiple layers of
corrugated metal plates, with two media running in alternate layers, transferring heat
from one media to another. The plates are either smooth or have some form of
corrugation, and they are either flat or wound in an exchanger.
The importance of the plate heat exchanger can be seen through the various
structural advantages it has to offer. This has a more advantage over a conventional
heat exchanger in that the fluids are exposed to a much larger area surface area
because the fluids spread out over the plates. This facilities the transfer of heat, and
greatly increases the speed of the temperature change. The heat transfer coefficients
obtained are significantly higher than the other heat exchangers for comparable fluid
conditions, which lead to a much smaller thermal size. Because of their high heat
transfer coefficients and true-counter flow arrangement, PHEs are able to operate
under very close approach temperature conditions which results in up to 90% heat
recovery.
Heat Exchanger |

Generally, this cannot accommodate very high pressures, temperatures, or

pressure and temperature differences. This type of exchanger is ideal for applications
where the fluids have relatively low viscosity with no particles. Also they are an ideal
choice where there is a close approach between product outlet temperature and
service inlet temperature.
MAJOR APPLICATIONS
Plate heat exchangers were introduced in 1923 for milk pasteurization
applications and now find major applications in liquidliquid (viscosities up to 10 Pa.s)
heat transfer duties. They are most common in the dairy, juice, beverage, alcoholic
drink, general food processing, and pharmaceutical industries, where their ease of
cleaning and the thermal control required for sterilization/pasteurization make them
ideal.
They are also used in the synthetic rubber industry, paper mills, and in the process
heaters, coolers, and closed-circuit cooling systems of large petrochemical and power
plants. Here heat rejection to seawater or brackish water is common in many
applications, and titanium plates are then used. Plate heat exchangers are not well
suited for lower-density gas-to-gas applications. They are used for condensation or
evaporation of non-low-vapor densities. Lower vapor densities limit evaporation to
lower outlet vapor fractions. Specially designed plates are now available for
condensing as well as evaporation of high-density vapors such as ammonia, propylene,
and other common refrigerants, as well as for combined evaporation/condensation
duties, also at fairly low vapor densities.
Heat Exchanger |

IMPORTANT PARTS/ BASIC CONSTRUCTION OF PLATE AND FRAME HEAT EXCHANGER
The plate heat exchanger consists of

a pack of corrugated metal plates
with portholes/ flowports for the
passage of the two fluids between
with which heat transfer will take
place. The plate pack is assembled
between a fix frame plate and a
movable
pressure
plate
and
compressed by tightening bolts.
Figure 1: Plate and Frame Heat Exchanger
Figure 2: Plates with Gaskets Around the Port
The plates are fitted with a gasket which seals the interpolate channel and directs the
fluids into alternate channels. The arrangement of the gaskets (field and ring gaskets)
results in through flow in single channels, so that the primary and secondary media are
Heat Exchanger |

in counter-current flow. The media cannot be mixed because of the gasket design. The
number of plates is determined by the flow rate, physical properties of the fluids,
pressure drop and temperature program. The plate corrugations promote fluid
turbulence and support the plates against differential pressure. This turbulence, in
association with the ratio of the volume of the media to the size of heat exchanger,
gives an effective heat transfer coefficient.
The plate and the pressure plate are suspended from an upper carrying bar and
located by a lower guiding bar, both of which are fixed to a support column, to ensure
proper alignment. The carrying bars are longer than the compressed stack, so that
when the movable end cover is removed, plates may be slid along the support bars for
inspection and cleaning.
MECHANISM/ DIRECTION OF FLOW

Typically, plate and
frame
heat
exchangers are used for liquid-liquid
exchange at low to medium pressures.
The heated liquid flows in one

direction in one set of plates and the
cool liquid flows in the opposite
direction in the other set. The heat
radiating from the hot set will be
absorbed by the cool liquid in the
second set. As the energy leaves the
hot media it cools off, and as it enters
the cold media it warms it.
ADVANTAGES AND LIMITATIONS

Some advantages of plate heat exchangers are as follows:
They can easily be taken apart into their individual components for cleaning,
inspection, and maintenance.
Heat Exchanger |

The heat transfer surface area can readily be changed or rearranged for a
different task or for anticipated changing loads, through the flexibility of plate
size, corrugation patterns, and pass arrangements.
High shear rates and shear stresses, secondary flow, high turbulence, and mixing
due to plate corrugation patterns reduce fouling to about 10 to 25% of that of a
shell-and-tube exchanger, and enhance heat transfer.
Because of high heat transfer coefficients, reduced fouling, the absence of

bypass and leakage streams, and pure counterflow arrangements, the surface
area required for a plate exchanger is one-half to one-third that of a shell-and
tube exchanger for a given heat duty, thus reducing the cost, overall volume,
and space requirement for the exchanger.
Leakage from one fluid to the other cannot take place unless a plate develops a
hole. Since the gasket is between the plates, any leakage from the gaskets is to
the outside of the exchanger.
The residence time (time to travel from the inlet to the outlet of the exchanger)
for different fluid particles or flow paths on a given side is approximately the
same. This parity is desirable for uniformity of heat treatment in applications such
as sterilizing, pasteurizing, and cooking.
There are no significant hot or cold spots in the exchanger that could lead to the
deterioration of heat-sensitive fluids. The volume of fluid held up in the exchanger
is small; this feature is important with expensive fluids, for faster transient response,
and for better process control.
Finally, high thermal performance can be achieved in plate exchangers. The
high degree of counterflow in PHEs makes temperature approaches of up to 18C
(28F) possible. The high thermal effectiveness (up to about 93%) facilitates
economical low-grade heat recovery. The flow-induced vibrations, noise,
thermal stresses, and entry impingement problems of shell-and-tube exchangers
do not exist for plate heat exchangers.
Heat Exchanger |

Some inherent limitations of the plate heat exchangers are caused by plates and
gaskets as follows:
The plate exchanger is capable of handling up to a maximum pressure of about

3 MPa gauge (435 psig) but is usually operated below 1.0 MPa gauge (150 psig).
Gasket life is sometimes limited. Frequent gasket replacement may be needed in
some applications.
Pinhole leaks are hard to detect. For equivalent flow velocities, pressure drop in a
plate exchanger is very high compared to that of a shell-and-tube exchanger.
PHEs are not suited for high-vacuum applications. PHEs are not suitable for
erosive duties or for fluids containing fibrous materials. In certain cases,
suspensions can be handled; but to avoid clogging, the largest suspended
particle should be at most one-third the size of the average channel gap.
Viscous fluids can be handled, but extremely viscous fluids lead to flow
maldistribution problems, especially on cooling. Plate exchangers should not be
used for toxic fluids, due to potential gasket leakage.
Heat Exchanger |
10

DOUBLE PIPE HEAT EXCHANGER
Double pipe heat exchanger is perhaps the simplest of all heat exchanger types.
A double pipe heat exchanger is just one pipe inside another larger pipe. One fluid
flows through the inside pipe and the other flows through the annulus between the two
pipes. The wall of the inner pipe is the heat transfer surface. The pipes are usually
doubled back multiple times in order to make the overall unit more compact.
DIVISION OF DOUBLE-PIPE HEAT EXCHANGERS
Double pipe exchangers are divided into two major types:
1.Single-tube
2. Multi-tube.
The Single-tube type consists of a single tube or pipe, either finned or bare, inside a
shell. Double-pipe sections permit true counter-current or true co-current flow, which
may be of particular advantage when very close temperature approaches or very long
temperature ranges are required. Multiple tube double pipe sections contain from 7 to
64 tubes, bare or longitudinally finned, within the outer pipe shell. Normally, it has only to
bare tubes are used in sections containing more than 19 tubes.
Heat Exchanger |
11

Double-pipe units are well suited for high pressure applications because of their
relatively small diameters. This allows the use of small flanges and thin wall sections, as
compared to conventional shell and tube equipment.
MAJOR APPLICATIONS
Double pipe heat exchangers are often used in the chemical, food processing and oil
& gas industries. They have a particular advantage when close temperature
approaches are needed or in high pressure applications.
1.
2.
3.
4.
5.
Pasteurization
Digester heating
Heat recovery
Pre-heating
Effluent cooling.
Double pipe heat exchangers are used when the heat transfer area is small. If we
connect them in series to increase the heat transfer area it will require much space as
well the pressure drop will be higher due to more fittings. Also, we cant increase no of
passes for either side fluids. In addition, the double pipe heat exchanger cant be used
for dirty fluids due to choking and cleaning is tougher.
MECHANISM/ DIRECTION OF FLOW
Heat Exchanger |
12

In designing double pipe heat exchanger, an important factor is the type of flow
pattern in the heat exchanger. A double pipe heat exchanger will typically be either
counterflow or parallel flow. Crossflow just doesn't work for a double pipe heat
exchanger.
A primary advantage of a double pipe heat exchanger is that it can be
operated in a true counterflow pattern, which is the most efficient flow pattern. That is,
it will give the highest overall heat transfer coefficient for the double pipe heat
exchanger design.
Also, double pipe heat exchangers can handle high pressures and temperatures
well. When they are operating in true counterflow, they can operate with a
temperature cross, that is, where the cold side outlet temperature is higher than the hot
side outlet temperature.
For example, in the diagrams, consider Fluid 1 to be the hot fluid and Fluid 2 to be the
cold fluid. Then, in the counterflow diagram, you can see that the cold side outlet
temperature, T2out, can approach the hot side entering temperature, T1in, which is higher
than the hot side outlet temperature, T2out. For the parallel flow shown, T2out can only
approach T1out; it could not be greater.
ADVANTAGES AND LIMITATIONS
Some of the advantages of the double pipe heat exchanger are:
Easy to operate.
Counter currents are obtained easily.
It can withstand high pressure and temperature.
Heat Exchanger |
13

Modular structure.
Maintenance is easy and repairing also easy
Easily displace from one place to another if required.
It can be adjusted according to the process need.
Occupy less space.
Structure is simple and heat transmission is large.
Provides shorter deliveries than shell and tube due to standardization of design and
construction.
Many suppliers are available worldwide
Some of the limitations are:
Double pipe heat exchanger is expensive for heavy duties.

The use of two single flow areas leads to relatively low flow rates and moderate
temperature differences.
Cant be used in handling dirty fluids.
It is difficult to readily inspect the shell side of the tubes for scaling or tube damage
Heat Exchanger |
14

EXTENDED SURFACE HEAT EXCHANGER

An extended surface (also known as a combined conduction-convection
system or a fin) is a solid within which heat transfer by conduction is assumed to be one
dimensional, while heat is also transferred by convection (and/or radiation) from the
surface in a direction transverse to that of conduction.
Some typical fin configurations
Straight fins of (a) uniform and (b) non-uniform cross sections; (c) annular
fin, and (d) pin fin of non-uniform cross section.
Extended surfaces have fins attached to the primary surface on one side of a
two-fluid or a multi-fluid heat exchanger. Fins can be of a variety of geometryplain,
wavy or interruptedand can be attached to the inside, outside or to both sides of
circular, flat or oval tubes, or parting sheets. Fins are primarily used to increase the
surface area (when the heat transfer coefficient on that fluid side is relatively low) and
consequently to increase the total rate of heat transfer. In addition, enhanced fin
geometries also increase the heat transfer coefficient compared to that for a plain fin.
Fins may also be used on the high heat transfer coefficient fluid side in a heat
exchanger primarily for structural strength (for example, for high pressure water flow
through a flat tube) or to provide a thorough mixing of a highly-viscous liquid (such as
for laminar oil flow in a flat or a round tube). Fins are attached to the primary surface by
brazing, soldering, welding, adhesive bonding or mechanical expansion, or extruded or
integrally connected to tubes.
Heat Exchanger |
15

Types of Extended Surface Heat Exchanger
1. Finned Tube Heat Exchanger

Finned Tube Heat Exchangers consist of a shell & finned tubes assembly. Fins are
used to increase the effective surface area of heat exchanger tubing. Finned tubes
are used when the heat transfer coefficient on the outside of the tubes is
appreciably lower than that on the inside; as in heat transfer from a liquid to a gas,
vapor to a gas, such as steam to air heat exchanger, thermic fluid to air heat
exchanger. When an extended surface is needed on only one fluid side (such as in
a gas to liquid exchanger) or when the operating pressure needs to be contained
on one fluid side, a finned tube heat exchanger may be selected.
Types of finned tube heat exchanger
a. Low Finned tube
The low finned tube commonly used in shell and tube exchangers
provides about 3 to 4 times as much as outside area as inside. The outside
diameter of the fins is just slightly less than that of the bare tube at the ends, so
the tube can be inserted through the tube sheet holes. The wall under the fins is
controlled to a specified thickness and the wall at the plain ends is about two
gauges heavier.
Low finned tubes are used for condensing organic vapors, which have
condensing coefficients only a third or a quarter of that of the cooling water
inside the tubes. In addition to providing additional heat transfer area, the fins
Heat Exchanger |
16

provide drip points that facilitate the drainage of the condensate. On the other
hand, finned tubes are not used for condensing steam or high surface tension
fluids on the fin side. The high surface tension causes the liquid to hang on the
surface, largely insulating it by a static film of liquid.
b. Medium Fin tube
A medium fin height tube with 11 fins per inch is also used in shell and tube
exchangers.
Medium finned tubes are used in variety of sensible, condensing And
boiling services in shell and tube exchangers. A typical sensible heat transfer
application would be cooling a compressed gas in a compressor intercooler,
using cooling water in the tubes.
c. High fin tube
The high fin tube is used to advantage when gases are to be heated or
cooled or when a process stream is to be air-cooled. High fin tubes come in a
wide variety of fin heights, thicknesses and spacing. For corrosion protection, a
mechanically bonded liner tube may be used inside the finned tube. The liner
can be made of corrosion-resistant alloy, while the other tubes and fins are
made of high conductivity metal such as copper or aluminum to improve heat
transfer.
One major application of high finned tubes is in air-cooled heat
exchangers. Atmospheric air, like all low pressure gases, gives very low heat
transfer coefficient at normal velocities. By contrast, the side tube fluid, usually a
fluid to be sensibly cooled or a vapor to be condensed may have a coefficient
up to 100 times higher or even more. Therefore, high finned tubes are used in
these exchangers to reduce the overall size of exchanger required. Even so,
some of these installations cover several acres.
2. Plate Fin Heat Exchanger
This type of heat exchanger uses "sandwiched" passages containing fins to
increase the effectiveness of the unit. The designs include cross flow and counter
Heat Exchanger |
17

flow coupled with various fin configurations such as straight fins, offset fins and wavy
fins.
Plate fin heat exchangers are usually made of aluminum alloys, which provide
high heat transfer efficiency. The material enables the system to operate at a lower
temperature difference and reduce the weight of the equipment.
Corrugations (Fins)
Corrugations are also made with heat transfer enhancement devices.
a. Plain corrugation is the basic form and is used normally for low pressure
drop streams.
b. Perforated corrugation shows a slight increase in performance over plain
corrugation, but this is reduced by the loss of area due to perforation. The
main use is to permit migration of fluid across fin channels, usually in
boiling duties.
c. Serrated corrugation is made by cutting the fins every 3.2 mm and
displacing the second fin to a point half way between the preceding fins.
This gives a dramatic increase in heat transfer.
d. Herringbone corrugation is made by displacing the fins sideways every 9.5
mm to give a zigzag path. Performance is intermediate between the plain
and serrated forms. The friction factor continues to fall at high Reynolds
numbers, unlike the serrated, showing advantages at higher velocities
and pressures.
The designer can, therefore, vary fin heights, fin pitch and fin thickness
together with four standard fin types giving great versatility of design.
Heat Exchanger |
18

Direction of Flow
Plate-fin units are normally arranged for counter flow heat exchange. Cross flow
units are used for vehicle radiators and cross counter flow is used for liquid sub coolers.
Finned tube units are arranged for cross flow heat exchange.
Advantages
Extended surfaces may exist in many situations but are commonly used as fins to
enhance heat transfer by increasing the surface area available for convection (and/or
radiation). They are particularly beneficial when the heat transfer coefficient on that
fluid side is relatively low is small, as for a gas and natural convection.
High heat transfer efficiency especially in gas treatment

Larger heat transfer area
Able to withstand high pressure
Limitations
Might cause clogging as the pathways are very narrow

Difficult to clean the pathways
Heat Exchanger |
19

Application
Plate and fin heat exchangers are mostly used for low temperature services such
as natural gas, helium and oxygen liquefaction plants, air separation plants and
transport industries such as motor and aircraft engines.
Applications of finned tube heat exchangers include Steam air heater / steam
radiator, Thermic fluid air heater / thermic fluid radiator, Hot water air heater / hot water
radiator, Air heater for fluid bed dryers, Air heater for spray dryers, Air heater for flash
dryers and Air heater for dryers. These are manufactured using high grade carbon
steel, stainless steel, copper, brass and aluminum.
Finned tubes are also used in boiling services, especially when condensing steam
is the heating medium inside the tubes. The condensing coefficient in this case may be
2000 or 3000 btu/hr.ft2.F, so even the high heat transfer coefficients commonly
associated with nucleate boiling may be relatively small by comparison and the design
can benefit by the use of low-finned tubes.
Heat Exchanger |
20

SHELL-AND-TUBE HEAT EXCHANGER (STHE)

The shell-and-tube heat exchanger is the most commonly used heat exchanger. It is
considered as the workhorse of the industrial process heat transfer (Minton, 1990). It is
widely used as a power condenser, oil cooler, preheater, and steam generator. Shelland-tube heat exchanger consists of many tubes mounted parallel to each other in a
tube sheet, like a bundle, and this tube bundle is enclosed by a cylindrical shell or
casing. The flow may be parallel, counter-current, or crossow and in some cases
combinations of these ow arrangements as a result of baffling. Shell and tube designs
are relatively simple and most often designed according to the Tubular Exchanger
Manufacturers Association (TEMA) standards .
Figure 1: Shell-and-Tube Exchanger
Trivia: Tubular Exchanger Manufacturers Association (TEMA) is an

association of manufacturers of shell-and-tube heat exchangers. TEMA
has established a set of construction standards for STHE. The Standards
are regularly updated and published; the most recent edition is the
ninth, published in 2007.
Heat Exchanger |
21

The Standards recognize three classes of heat exchanger construction:
Class R for the severe requirements of petroleum processing (and usually including
most large scale processing applications)
Class C for general commercial application
Class B for chemical process service
Advantages of Using Shell-and-Tube Heat Exchangers

The shell and tube heat exchanger provides a comparatively large ratio of heat
transfer area to volume and weight. It can be easily constructed from a wide range of
sizes and the shell and the tubes can be made of different materials.There is substantial
flexibility regarding materials of construction to accommodate corrosion and other
concerns. In addition to this, there are many modifications of basic configuration which
can be used to solve special problems. Extended heat transfer surfaces (fins) can be
used to enhance heat transfer. The pressures and pressure drops can be varied over a
wide range. Thermal stresses can be accommodated inexpensively. Condensation or
boiling heat transfer can be accommodated in either the tubes or the shell, and the
orientation can be horizontal or vertical. It can be reasonably easily cleaned, and those
components most subject to failure, like gaskets and tubes, can be easily replaced
because it can be dismantled.
Major Parts of a Shell-and-Tube Heat Exchanger

The shell-and-tube exchanger consists of four major parts:
Front Header - This is where the fluid enters the tube side of the exchanger. It is
sometimes referred to as the Stationary Header.
Shell - This contains the tube bundle.
Tube bundle - This comprises of the tubes, tube sheets, and baffles, etc. to hold the
bundle together.
Heat Exchanger |
22

Rear Header - This is where the tube side fluid leaves the exchanger or where it is
returned to the front header in exchangers with multiple tube side passes.
Figure 2: Major Parts of a Shell-and-Tube Heat Exchanger
Parts of a Tube Bundle:
Tubes - Tubing that is generally used in TEMA sizes is made from low carbon steel,
copper, Admiralty, Copper-Nickel, stainless steel, Hastalloy, Inconel, titanium and a
few others. It is common to use tubing from 5/8 to 1-1/2 in these designs. Tubes
are generally drawn and seamless, but welded tubes with superior grain structure at
the weld are also common. The two types of tubes are straight and U-tubes.
Tube Sheet - This is usually made from a round flat piece of metal with holes drilled
for the tube ends in a precise location and pattern relative to one another. Tubes
are attached to the tube sheet by pneumatic or hydraulic pressure or by roller
expansion. Tube holes are typically drilled and then reamed and can be machined
with one or more grooves.
Heat Exchanger |
23

(a)
(b)
Figure 3: (a) photo of a tube sheet (b) diagram of tube sheet and tube assembly
Baffle - This support the tubes during assembly and operation and help prevent
vibration from flow induced eddies and direct the shell side fluid back and forth
across the tube bundle to provide effective velocity and heat transfer rates. There
are a number of different baffle types, which support the tubes and promote flow
across the tubes.
Single Segmental (this is the most common)
Double Segmental (this is used to obtain a lower shell side velocity and pressure
drop)
Disc and Doughnut
Figure 4: Types of Baffles
Heat Exchanger |
24

Tie Rods and Spacers - These hold the baffle assembly together and maintain the
selected baffle spacing. The tie rods are secured at one end to the tube sheet
and at the other end to the last baffle. They hold the baffle assembly together. The
spacers are placed over the tie rods between each baffle to maintain the selected
baffle pitch. The minimum number of tie rod and spacers depends on the diameter
of the shell and the size of the tie rod and spacers.
Figure 5: Outer and Inner Parts of STHE
Common Types of Shell-and-Tube Heat Exchanger

U-Tube heat exchanger
Heat Exchanger |
25

It is bent in the shape of U and has only one tube sheet. The shell diameter is larger
due to the minimum U-bend radius. The advantage of this type is that one end is free,
the bundle can expand or contract in response to stress differentials. In addition, the
outsides of the tubes can be cleaned, as the tube bundle can be removed. The
drawbacks of this construction is that individual tubes can be difficult of expensive to
replace, especially for interior tubes. Also, the tube interior cannot be effectively
cleaned in the U-bends. Erosion damage is also frequently seen in the U-bends in high
tube side velocity applications. In large diameter shells, the long length of unsupported
tube in the U-bends of outer tubes can lead to vibration induced damage. Steam
generator used in pressurized water reactor in nuclear power plants typically have Utubes.
Single-Pass shell-and-tube heat exchanger
The fluid flowing through the tubes enters a header or channel where it is distributed
through the tubes in parallel flow and leaves the unit through another header in one
pass. While the other fluid enters the other end of the shell and flows counter-flow
across the outside of the tubes. Cross-baffles are used so that the fluid is forced to flow
perpendicular across the tube bank rather than parallel with it. Surface condensers in
power plants are often singe-pass heat exchangers.
Heat Exchanger |
26

Multi-Pass shell-and-tube heat exchanger
In a two-pass heat exchanger, the fluid enters and exit on the same side of the
heat exchanger. There are many different types or designs of shell-and-tube heat
exchangers to meet various process requirements. STHEs can provide steady heat
transfer by utilizing multiple passes of one or both fluids.
TEMA Designation for Shell-and-Tube Heat Exchangers

The popularity of shell and tube exchangers has resulted in a standard
nomenclature being developed for their designation and use by the Tubular Exchanger
Manufactures Association (TEMA). This nomenclature is defined in terms letters and
diagrams. The first letter describes the front header type, the second letter the shell type
and the third letter the rear header.
Heat Exchanger |
27

Table 1. Shell and tube geometric terminology

Fixed Tube Sheet
Exchangers
U-tube Exchangers
AEL
BEL
AEU
AEM
BEM
CEU
AEN
BEN
DEU
Floating Head Exchangers
AES
BES
Essentially there are three main combinations:
A. Fixed Tubesheet Exchanger (L, M, and N Type Rear Headers)

In a fixed tube sheet exchanger, the tube sheet is welded to the shell. This results in
a simple and economical construction and the tube bores can be cleaned
mechanically or chemically. However, the outside surfaces of the tubes are
inaccessible except to chemical cleaning. If large temperature differences exist
between the shell and tube materials, it may be necessary to incorporate an expansion
bellows in the shell, to eliminate excessive stresses caused by expansion. Such bellows
are often a source of weakness and failure in operation. In circumstances where the
consequences of failure are particularly grave U-Tube or Floating Header units are
normally used. This is the cheapest of all removable bundle designs, but is generally
slightly more expensive than a fixed tube sheet design at low pressures.
B. U-Tube Exchangers
In a U-Tube exchanger any of the front header types may be used and the rear
header is normally a M-Type. 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.
Heat Exchanger |
28

C. Floating Head Exchanger (P, S, T and W Type Rear Headers)

In this type of exchanger the tube sheet at the Rear Header end is not welded to
the shell but allowed to move or float. The tube sheet at the Front Header (tube side
fluid inlet end) is of a larger diameter than the shell and is sealed in a similar manner to
that used in the fixed tube sheet design. The tube sheet at the rear header end of the
shell is of slightly smaller diameter than the shell, allowing the bundle to be pulled
through the shell. The use of a floating head means that thermal expansion can be
allowed for and the tube bundle can be removed for cleaning. There are several rear
header types that can be used but the S-Type Rear Head is the most popular. A floating
head exchanger is suitable for the rigorous duties associated with high temperatures
and pressures but is more expensive (typically of order of 25% for carbon steel
construction) than the equivalent fixed tube sheet exchanger.
Considering each header and shell type in turn:

A-Type front header: This type of header is easy to repair and replace. It also gives
access to the tubes for cleaning or repair without having to disturb the pipe work. It
does however have two seals (one between the tube sheet and header and the other
between the header and the end plate). This increases the risk of leakage and the cost
of the header over a B-Type Front Header.
B-Type front header: This is the cheapest type of front header. It also is more suitable
than the A-Type Front Header for high pressure duties because the header has only one
seal. A disadvantage is that to gain access to the tubes requires disturbance to the
pipe work in order to remove the header.
C-Type front header: This type of header is for high pressure applications (>100 bar). It
does allow access to the tube without disturbing the pipe work but is difficult to repair
and replace because the tube bundle is an integral part of the header.
D-Type front header: This is the most expensive type of front header. It is for very high
pressures (> 150 bar). It does allow access to the tubes without disturbing the pipe work
but is difficult to repair and replace because the tube bundle is an integral part of the
header.
N-Type front header: The advantage of this type of header is that the tubes can be
accessed without disturbing the pipe work and it is cheaper than an A-Type Front
Header. However, they are difficult to maintain and replace as the header and tube
sheet are an integral part of the shell.
Heat Exchanger |
29

Y-Type front header: Strictly speaking this is not a TEMA designated type but is generally
recognized. It can be used as a front or rear header and is used when the exchanger is
to be used in a pipe line. It is cheaper than other types of headers as it reduces piping
costs. It is mainly used with single tube pass units although with suitable partitioning any
odd number of passes can be allowed.
E-Type shell: This is most commonly used shell type, suitable for most duties and
applications. Other shell types only tend to be used for special duties or applications.
F-Type shell: This is generally used when pure counter-current flow is required in a two
tube side pass unit. This is achieved by having two shells side passesthe two passes
being separated by a longitudinal baffle. The main problem with this type of unit is
thermal and hydraulic leakage across this longitudinal baffle unless special precautions
are taken.
G-Type shell: This is used for horizontal thermosiphon reboilers and applications where
the shell side pressure drop needs to be kept small. This is achieved by splitting the shell
side flow.
H-Type shell: This is used for similar applications to G-Type Shell but tends to be used
when larger units are required.
J-Type shell: This tends to be used when the maximum allowable pressure drop is
exceeded in an E-Type Shell even when double segmental baffles are used. It is also
used when tube vibration is a problem. The divided flow on the shell side reduces the
flow velocities over the tubes and hence reduces the pressure drop and the likelihood
of tube vibration. When there are two inlet nozzles and one outlet nozzle this is
sometimes referred to as an I-Type Shell.
K-Type shell: This is used only for reboilers to provide a large disengagement space in
order to minimize shell side liquid carry over. Alternatively a K-Type Shell may be used as
a chiller. In this case the main process is to cool the tube side fluid by boiling a fluid on
the shell side.
X-Type shell: This is used if the maximum shell side pressure drop is exceeded by all other
shell and baffle type combinations. The main applications are shell side condensers and
gas coolers.
L-Type rear header: This type of header is for use with fixed tube sheets only, since the
tube sheet is welded to the shell and access to the outside of the tubes is not possible.
The main advantages of this type of header are that access can be gained to the
inside of the tubes without having to remove any pipework and the bundle to shell
clearances are small. The main disadvantage is that a bellows or an expansion roll are
Heat Exchanger |
30

required to allow for large thermal expansions and this limits the permitted operating
temperature and pressure.
M-Type rear header: This type of header is similar to the L-Type Rear Header but it is
slightly cheaper. However, the header has to be removed to gain access to the inside
of the tubes. Again, special measures have to be taken to cope with large thermal
expansions and this limits the permitted operating temperature and pressure.
N-Type rear header: The advantage of this type of header is that the tubes can be
accessed without disturbing the pipe work. However, they are difficult to maintain and
replace since the header and tube sheet are an integral part of the shell.
P-Type rear header: This is an outside packed floating rear header. It is, in theory, a low
cost floating head design which allows access to the inside of the tubes for cleaning
and also allows the bundle to be removed for cleaning. The main problems with this
type of header are large bundle to shell clearances required in order to pull the bundle,
limited to low pressure nonhazardous fluids, because it is possible for the shell side fluid
to leak via the packing rings, and only small thermal expansions are permitted. In
practice it is not a low cost design, because the shell has to be rolled to small
tolerances for the packing to be effective.
S-Type rear header: This is a floating rear header with backing device. It is the most
expensive of the floating head types but does allow the bundle to be removed and
unlimited thermal expansion is possible. It also has smaller shell to bundle clearances
than the other floating head types. However, it is difficult to dismantle for bundle pulling
and the shell diameter and bundle to shell clearances are larger than for fixed head
type exchangers.
T-Type rear header: This is a pull through floating head. It is cheaper and easier to
remove the bundle than with the S-Type Rear Header, but still allows for unlimited
thermal expansion. It does, however, have the largest bundle to shell clearance of all
the floating head types and is more expensive than fixed header and U-tube types.
U-tube: This is the cheapest of all removable bundle designs, but is generally slightly
more expensive than a fixed tube sheet design at low pressures. However, it permits
unlimited thermal expansion, allows the bundle to be removed to clean the outside of
the tubes, has the tightest bundle to shell clearances and is the simplest design. A
disadvantage of the U-tube design is that it cannot normally have pure counter flow
unless an F-Type Shell is used. Also, U-tube designs are limited to even numbers of tube
passes.
W-Type rear header: This is a packed floating tube sheet with lantern ring. It is the
cheapest of the floating head designs, allows for unlimited thermal expansion and
Heat Exchanger |
31

allows the tube bundle to be removed for cleaning. The main problems with this type of
head are: the large bundle to shell clearances required to pull the bundle and; the
limitation to low pressure nonhazardous fluids (because it is possible for both the fluids to
leak via the packing rings). It is also possible for the shell and tube side fluids to become
mixed if leakage occurs.
Applications of Shell-and-Tube Heat Exchangers

Shell and tube heat exchangers represent the most widely used vehicle for the
transfer of heat in industrial process applications. They are frequently selected for such
duties as:
Process liquid or gas cooling
Process refrigerant vapor or steam condensing
Process liquid, steam or refrigerant evaporation
Process heat removal and preheating of feed water
Thermal energy conservation efforts, heat recovery
Compressor, turbine and engine cooling, oil and jacket water
Hydraulic and lube oil cooling
Heat Exchanger |
32

TEMA Designations for Shell-and-Tube Heat Exchangers
Heat Exchanger |
33

References
Basic Construction of Shell and Tube Heat Exchangers. Retrieved July 2, 2015 from
http://local.alfalaval.com/en-us/key-technologies/heat-transfer/shell-and-tube-heatexchangers/process-industrial/Documents/TEMA%20basics%20of%20construction%20%2007.10.pdf
Bell, K.J. (2011). TEMA Standards. Retrieved June 30, 2015, from
http://www.thermopedia.com/content/1182/
Brogan, R.J. (2011). Shell and Tube Heat Exchangers. Retrieved June 30, 2015, from
http://www.thermopedia.com/content/1121/
Heat Exchangers. Retrieved July 2, 2015, from
http://web.pdx.edu/~yongkang/main/class/Heat%20Exchangers.pdf
Kuppan, T. (2000). Heat Exchanger Design Handbook. New York: Marcel Dekker Inc.
Heat Exchanger |
34

Heat Exchanger

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Heat Exchanger

Uploaded by

Copyright:

Available Formats

PAMANTASAN NG LUNGSOD NG MAYNILA

University of the City of Manila

Introduction to HEAT EXCHANGERS

PAMANTASAN NG LUNGSOD NG MAYNILA

PAMANTASAN NG LUNGSOD NG MAYNILA

Basic Heat Exchanger Flow Arrangements

PAMANTASAN NG LUNGSOD NG MAYNILA

PAMANTASAN NG LUNGSOD NG MAYNILA

PLATE AND FRAME HEAT EXCHANGER (PHE)

PAMANTASAN NG LUNGSOD NG MAYNILA

Generally, this cannot accommodate very high pressures, temperatures, or

PAMANTASAN NG LUNGSOD NG MAYNILA

IMPORTANT PARTS/ BASIC CONSTRUCTION OF PLATE AND FRAME HEAT EXCHANGER

The plate heat exchanger consists of

Figure 1: Plate and Frame Heat Exchanger

Figure 2: Plates with Gaskets Around the Port

PAMANTASAN NG LUNGSOD NG MAYNILA

MECHANISM/ DIRECTION OF FLOW

The heated liquid flows in one

ADVANTAGES AND LIMITATIONS

PAMANTASAN NG LUNGSOD NG MAYNILA

Because of high heat transfer coefficients, reduced fouling, the absence of

PAMANTASAN NG LUNGSOD NG MAYNILA

The plate exchanger is capable of handling up to a maximum pressure of about

PAMANTASAN NG LUNGSOD NG MAYNILA

DOUBLE PIPE HEAT EXCHANGER

PAMANTASAN NG LUNGSOD NG MAYNILA

PAMANTASAN NG LUNGSOD NG MAYNILA

PAMANTASAN NG LUNGSOD NG MAYNILA

Some of the limitations are:

Double pipe heat exchanger is expensive for heavy duties.

PAMANTASAN NG LUNGSOD NG MAYNILA

EXTENDED SURFACE HEAT EXCHANGER

PAMANTASAN NG LUNGSOD NG MAYNILA

Types of Extended Surface Heat Exchanger

1. Finned Tube Heat Exchanger

PAMANTASAN NG LUNGSOD NG MAYNILA

PAMANTASAN NG LUNGSOD NG MAYNILA

PAMANTASAN NG LUNGSOD NG MAYNILA

High heat transfer efficiency especially in gas treatment

Might cause clogging as the pathways are very narrow

PAMANTASAN NG LUNGSOD NG MAYNILA

PAMANTASAN NG LUNGSOD NG MAYNILA

SHELL-AND-TUBE HEAT EXCHANGER (STHE)

Figure 1: Shell-and-Tube Exchanger

Trivia: Tubular Exchanger Manufacturers Association (TEMA) is an

PAMANTASAN NG LUNGSOD NG MAYNILA

The Standards recognize three classes of heat exchanger construction:

Class C for general commercial application

Class B for chemical process service

Advantages of Using Shell-and-Tube Heat Exchangers

Major Parts of a Shell-and-Tube Heat Exchanger

Shell - This contains the tube bundle.

PAMANTASAN NG LUNGSOD NG MAYNILA

Figure 2: Major Parts of a Shell-and-Tube Heat Exchanger

Parts of a Tube Bundle:

PAMANTASAN NG LUNGSOD NG MAYNILA

Single Segmental (this is the most common)

Disc and Doughnut

Figure 4: Types of Baffles

PAMANTASAN NG LUNGSOD NG MAYNILA

Figure 5: Outer and Inner Parts of STHE

Common Types of Shell-and-Tube Heat Exchanger

PAMANTASAN NG LUNGSOD NG MAYNILA