Heat Transfer

and
Heat Exchangers

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Please could you tell us:

•Your name
•Your organisation and job
•Your state and language
•Your Expectation from the
course

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 GroundRules
 Respect the Autonomy of Others

 All phones on silence mode or switch of mode

 Only One Person to Speak at a time

 Be Open Minded

 Share knowledge

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COURSE SUMMARY
 Introduction
 Understanding of Heat Transfer principles
 Types of Heat Exchanger
 Uses in chemical processes
 Classification of heat exchangers according to flow
 Integration of fouling considerations and performance
monitoring
 Operation ,Troubleshooting and maintenance
activities

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COURSE OBJECTIVE
 Understand heat transfer fundamentals
 Analyze exchanger operational parameters
 Determine correct troubleshooting techniques
 Determine the correct selection criteria for heat
exchangers
 Troubleshoot exchange problems and solve them

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SAFETY SHOULD GUIDE ALWAYS
 Always ensure that you follow all safety procedures as
specified by operation and maintenance instruction as
specified by manufacturer.
 Ensure all Personal protective equipment is put on
 Ensure that the Heat exchanger inlet Valve is close and
TAG OUT before maintenance
 When opening up the heat exchanger for maintenance
ensure that the fluid are completely drain and allow to
cool down if hot process or if cooled heat exchanger ,
Ice is allowed to melt out
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Definition of Heat Transfer
 Heat is the transfer of kinetic energy from one
medium or object to another, or from an energy source
to a medium or object. Such energy transfer can occur
in three ways:
 Radiation
 Conduction
 Convection

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CONDUCTION
 Heat by conduction takes place when two material
media or objects are in direct contact, and the
temperature of one is higher than the temperature of
the other. The temperatures tend to equalize; thus the
heat conduction consists of a transfer of kinetic energy
from the warmer medium to the cooler one. An
example is the immersion of a chilled human body in a
hot bath.

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CONVENTION
 Heat by convection occurs when the motion of a liquid
or gas carries energy from a warmer region to a cooler
region. A good example of convection is the tendency
of warm air to rise and cool air to fall, equalizing the
air temperature inside a room containing a hot stove.

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 HEAT EXCHANGERS
 A mechanical device whose primary purpose is the
transfer of energy between two fluids is named a
Heat Exchanger.

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Types of Heat Exchanger
 Shell and tube
 Double pipe
 Plate
 Finned tubes/gas heaters
 spiral
 Vessel jackets
 Reboilers and vaporizers/evaporators
Etc
 Direct/indirect

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Applications :
 Air conditioning
 Refrigeration
 Chemical plants
 Petrochemical plants
 Sewage treatments
 Petroleum refineries
 CO2 Process plant

Common examples: Car radiator , Generator radiator

Refrigerator evaporator. & condenser.

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Heat Exchangers Selection
 Past experience, is always the best place to start to guide the
selection of heat exchanger types. Understanding the reasons
behind both successes and failures will lead to better equipment
selection.

 When comparing different types of heat transfer equipment, one

must take into consideration the total cost of the equipment
which includes:
 purchase cost
 installation cost
 operating cost (pumping, fan…)
 maintenance cost
 Type of fluid that will pass through the exchange

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 SHELL AND TUBE.
Shell & tube heat exchangers
Advantages
Widely known and understood
since it is the most common type
Most versatile in terms of types of
service
Widest range of allowable design
pressures and temperatures
Rugged mechanical construction -
can withstand more abuse
(physical and process)
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Disadvantages
Less thermally efficient than other types of
heat transfer equipment
Subject to flow induced vibration which Can
leadto equipment failure
Not well suited for temperature cross
conditions (multiple units in series must be
used)
Contains stagnant zones (dead zones) on the
shell side which can lead to corrosion
problems
Subject to flow mal-distribution especially with
two phase inlet streams
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 PLATE HEAT EXCHANGER
Compact Heat Exchangers
Advantages Disadvantages
Low initial purchase cost (plate type) Narrower rage of allowable pressures and temperatures

Many different configurations are available (gasketed, Subject to plugging/fouling due to very narrow flow path
semi-welded, welded, spiral)

High heat transfer coefficients (3 or more times greater Gasketed units require specialized opening and closing
than for shell & tube heat exchangers, due to much higher procedures
wall shear stress)

Tend to exhibit lower fouling characteristics due to the high Material of construction selection is critical since wall
turbulence within the exchanger thickness very thin (typically less than 10 mm)

True countercurrent designs allow significant temperature

crosses to be achieved

Require small footprint for installation and have small

volume hold-up

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Classification according to flow:
 Parallel flow H. E. : The two fluids enter the exchanger
at the same end, and travel in parallel to one another
to the other side.
 Counter Flow H.E. : the fluids enter the exchanger
from opposite ends.
 Cross Flow H.E. : the fluids travel roughly
perpendicular to one another through the exchanger.

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Major Types of Heat Exchangers
Shell and Tube Heat exchanger:
 Shell and tube heat exchangers are typically used for
high-pressure applications (with pressures greater
than 30 bar and temperatures greater than 260°C).
 Has tube side (tube bundle) and shell side.

Note: Tube or shell side can contain the fluid to be

cooled or heated. No one is stipulated to contain any it
all depends on design choice.

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KEY TERMS
 Tubes Tubing may be seamless or welded. Seamless tubing is produced in an
extrusion process; welded tubing is
 Tube sheets are plates or forgings drilled to provide holes through which tubes
are inserted. Tubes are appropriately secured to the tube sheet so that the fluid
on the shell side is prevented from mixing with the fluid on the tube
side. Holes are drilled in the tube sheet normally in either of two patterns,
triangular or square.
 Baffles serve three functions: 1) support the tube; 2) maintain the tube
spacing; and 3) direct the flow of fluid in the desired pattern through the shell
side.
 Tie rods and spacers are used for two reasons: 1) hold the baffle assembly
together; and 2) 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.
 Channels or heads are required for shell-and-tube heat exchangers to contain
the tube side fluid and to provide the desired flow path.

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 Plate Heat exchangers :
Composed of multiple, thin, slightly-separated plates that
have very large surface areas and fluid flow passages for heat
transfer.

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 PICTURES OF PLATE HEAT EXCHANGER

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FOULING IN HEAT EXCHANGERS
Occurs when impurities deposit on the heat exchange
surface.
Deposition of these impurities can be caused by:
 Low wall shear stress
 Low fluid velocities
 High fluid velocities
 Reaction product solid precipitation
 Precipitation of dissolved impurities due to elevated
wall temperatures

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FOULING IN HEAT EXCHANGERS
Note : Each H.E installed in the
plant has been designed to
accommodate a particular fluid
temperature and velocity or low
rate. A deviation can lead to
fouling. Therefore we must
monitor our temperature and
pressure gauges so that the fluid
temperature and velocity remain in
the set point.

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Some instances of fouling:
 Crude Oil Exchanger Fouling. In commercial crude
oil refining, crude oil is heated from 70F to 650F prior
to entering the distillation column. A series of shell
and tube heat exchangers is typically used to exchange
heat between the crude oil and other oil streams, in
order to get the crude to 500F prior to heating in a
furnace. Fouling occurs on the crude side of these
exchangers due to asphaltene insolubility.

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Cont.
 Cooling Water Fouling. Cooling water systems e.g in
the CO2 plant are susceptible to fouling. Cooling water
typically has a high total dissolved solids content and
suspended colloidal solids. Localized precipitation of
dissolved solids occurs at the heat exchange surface
due to wall temperatures higher than bulk fluid
temperature. Low fluid velocities allow suspended
solids to settle on the heat exchange surface.

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To prevent fouling :
 Designers typically ensure that cooling water velocity
is greater than 3 ft/s and bulk fluid temperature is
maintained less than 140F.
 Frequent application of biocides and anti-scale
chemicals with periodic lab testing.

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Maintenance of Heat Exchangers
 Plate heat exchangers need to be disassembled and
cleaned periodically according to manufactures
specification.
 Tubular heat exchangers can be cleaned by such
methods as acid cleaning, sandblasting, high-pressure
water jet , bullet cleaning, or drill rods.
 In large-scale cooling water systems for heat
exchangers, water treatment such as purification,
addition of chemicals, and testing, is used to minimize
fouling of the heat exchange equipment.

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MAINTENANCE
Daily checks
 During operation , check for leakages and report on Log
book if any
 Check for work loose bolt and Nut
 Check and ensure that temperature sensors, pressure
sensors, flow meter are working properly
 Check and ensure that pressure gauges and temperature
gauges are working properly and the reading is within
manufacturer recommendation
 Checking all chemical dosing pumps are working
 Weekly maintenance- Check and Clean strainers if dirty

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QUESTION AND ANSWER

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I indeed grateful for your time and the learning experience with
you all .I look forward to see you again in AETI

THANK YOU! THANK YOU!! THANK YOU!!!

Precious E.O.Adeho

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