Eng.

Ahmed Deyab Fares

Cooler
Reduce the temperature of a liquid or gas using water to remove heat.
Heater
Increase the temperature of a liquid or gas by adding heat using condensing steam, hot oil, etc.
Condenser
Remove heat from a gas, changing it to a liquid.
Evaporators
Employed for concentration of the solution by evaporation of water.
Reboilers
Provide heat as latent heat to liquid in the bottom of a distillation tower. The heat may be
supplied by either steam or a hot process stream.
Chiller
Cool a liquid or gas using a refrigerant instead of water.
Exchanger
Perform two functions. They can heat a cold process stream by using a hot
process fluid, or they can cool a hot process stream by using a cold process fluid.
 Naphtha
and gases

Naphtha
and gases
Top pump
Kerosene
Desalter around
Top pump E2

Distillation tower
around Heavy gas oil Light
gas oil
Bottom
E2 E3 pump
around
Heavy
Light gas oil E5
Kerosene gas oil
E4
E1 Bottom pump
Furnace
around
E5 E6
Reduced
crude
Storage Reduced crude
Device used to implement the process
of heat exchange between two fluids
that are at different temperatures and
separated by a solid wall.
 Between two streams to reduce the energy
consumption –Energy conservation principles
 Between one stream and the utility fluid- process
requirement.
 The service fluid may be steam supply or cooling
water supply or other heating and cooling media.
Modes of Heat Transfer
 Conduction
 Convection
 Radiation
 Conduction
Parameters affecting the rate of conductive heat
transfer
1- Temperature difference
2- Surface area
3- Thermal conductivity of material
 dT
Q cond  k A
dx
• k = thermal conductivity, W/m℃
• A = cross section area, m2
• dT/dx = temperature gradient, ℃/m
 Material k (Btu/hr. ft. F)
 Cork 0.025
 Fiber Insulating Board 0.028
 Maple or Oak Wood 0.096
 Building Brick 0.4
 Window Glass 0.45
 Concrete 0.79
 1% Carbon Steel 25
 1% Chrome Steel 35
 Aluminum 118
 Copper 223
 Silver 235
 Sat Steam ( 600 E F) 0.030
 Liquid Water (at 600 E F) 0.3
Convection
 Natural Convection
 Forced Convection
 Boiling
 Condensation
 Convection is the transfer of heat through the physical
movement of gaseous or liquid fluid.
 Convection heat transfer does not take place in solids
because their molecular structure is very dense and the
relative movement of molecules is very small relative to
that in gases and liquids.
 Qconv  h As Ts  T 

• h = convection heat transfer coefficient,
W/m2℃
• As = surface area, m2
• Ts = surface temperature, ℃
• T∞ = temperature of the fluid, ℃
Radiation
 Radiation is the emitted energy from the motion of
particles rather than the transmission of heat through
matter.
 The transfer of heat by radiation is experienced when
you feel the warmth of the sun; heat reaches the earth
from the sun by radiation.
Radiation
 The transfer of heat by radiation is identical to the
transfer of energy by light and by radio waves. In a
vacuum,
 radiation heat waves move at the speed of light,
approximately 186,000 miles/s.
 Qemit   AsTs
 4

  = emissivity of the surface

  = Stefan-Boltzmann Constant, 5.67×10-8 W/m2 K4
 As = surface area, m2
 Ts = surface temperature, ℃
Qrad   As Ts  Tsurr 
 4 4
 Factors affecting the radiative heat transfer
1- Temperature.
2- Surface area.
3- Emissivity
4- Configuration
Fluid U [Btu/ft2.hr.F]
Organics to Organics 10-60
Steam to:
Aqueous Solutions 100-600
Fuel Oil, Heavy 10-30
Light 30-60
Gases 5-50
Water 175-600
Water to:
Alcohol 50-150
Brine 100-200
Compressed Air 10-30
Fluid U [Btu/ft2.hr.F]
Condensing Alcohol 45-120
Condensing Ammonia 150-250
Condensing Freon-12 80-150
Condensing Oil 40-100
Gasoline 60-90
Lubricating Oil 20-60
Organic Solvents 50-150
Water 150-300
 A A A
B
B B
Counter Flow Parallel Flow Cross Flow

 Fluid A
 Fluid B
Changing in Temp. Changing in Phase
Ex. Car Radiator Ex. Reboiler
 Classification
According
to Transfer
Process (Type of
Contact)

Indirect Contact Direct Transfer

Heat Exchangers Type Exchangers
Direct contact Indirect contact
Ex. Cooling Tower Ex. Air Cooled condenser
Indirect Contact: - Direct Contact: -
• Shell And Tube • Cooling Tower
•Furnaces & Boilers
• Air Cooler
•Plate and Frame
•Spiral
 Classification
According
to Surface
Compactness

Compact Non-compact
 Classification
According
to Construction

Extended
Tubular
Plate heat surface
heat
exchangers heat
exchangers
exchangers

Plate Heat Exchangers are easy to clean by remove
the tie bolts and slide back the movable frame part.
Then the plate pack can be inspected, pressure
cleaned, or removed for refurbishment if required.

A very significant feature of the plate Heat
Exchanger is that it is expandable. Increasing the
Heat Transfer requirements means simply adding
plates instead of buying a new Heat Exchanger,
saving time and money.

Because of the pressed patterns in the plates and
the relative narrow gaps, very high turbulence is
achieved at relative low fluid velocity. This
combined with counter directional flow results
in very high Heat Transfer coefficients.

As a result of the high efficiency, less Heat Transfer area is required,
resulting in a much smaller Heat Exchanger than would be needed for
the same duty using other types of Heat Exchangers. Typically a plate
Heat Exchanger requires between 20-40% of the space required by a
tube & shell Heat Exchanger.

The same features that give the plate Heat Exchanger its high
efficiency also makes it possible to reach close approach temperatures
which is particularly important in heat recovery and regeneration
applications. Approach temperatures of 0.5°C is possible.

Very high turbulence is achieved as a result of
the pattern of the plates, the many contact
points, and the narrow gap between the plates.
This combined with the smooth plate surface
reduces fouling considerably compared to other
types of Heat Exchangers.

High Heat Transfer coefficients mean less Heat
Transfer area and smaller Heat Exchangers, and
sometimes even less Heat Exchanger.
 Indirect Contact Heat Exchangers
5- Plate and Frame: -
Advantages: -
• Easy Maintenance & disassembly.
• Plates could added or removed for difference service
conditions.
• Low fluid volume to surface area ratio.
• Fluid Leakage between streams can not be occur unless
material fails.
• Fluid leak due to defective gaskets is external and easily
detected.
• Low fouling is encountered due to the high turbulence.
• Very compact relative to shell and tube
• Low maintenance area needed
• Maintenance done without disassembling of connections
 Low upper limitations for temperature and

pressure.

• Care in maintenance.

• Gasket materials not compatible with all fluids.

 Its normally used in liquid services.

• It can be used for services requiring a low

pressure drop with the associated reduction in
Heat transfer coefficients.
The most common heat exchanger type : -
• Low Noise.
• Compact.
• Nearly all fluids.
• High temperature & pressure range.
1- Channel Cover 8- Shell
2- Channel 9- Baffles
3- Channel Flange 10- Floating Head backing Device
4- Pass Partition 11- Floating Tubesheet
5- Stationary Tubesheet 12- Floating Head
6- Shell Flange 13- Floating Head Flange
7- Tube 14 –Shell Cover
 Baffles are transverse or longitudinal plates
installed on the shell side of heat exchangers to
force the shell side fluid to flow across the tubes
in a specific pattern.

 The modified flow improves heat transfer

between the shell side and tube side fluids.
 Single Segmental (this is the most common),

 Double Segmental (this is used to obtain a lower

shellside velocity and pressure drop),

 Disc and Doughnut.

 TYPES OF BAFFLE PLATES

 have one fluid passage

cut through the baffle.
 Single segmental
baffles are prevalent in
heat exchangers in
which the shell side
fluid is a liquid
  have two and three
passages, respectively.
 They are generally
used when the shell
side fluid is a gas.

Segmental baffles can be cut horizontally or vertically.

 used to improve heat
transfer between shell
side fluid and tube side
fluid More than
segmental baffles.
.
13
4
 divide tube bundle and
shell Into two parts.
This done to achieve
multi-pass shell.
 IMPINGEMENT BAFFLE PLATES

Impingement Baffle are plates positioned under

the inlet nozzle of the shell to improve fluid
Distribution.

Impingement Baffle are used with gases and vapours

Condensers.
TUBE BUNDLE
 There are two basic
mechanical factors
which affect vapor
disengagement.
 Spacing and
arrangement of the
exchanger.
 And the area
available between the
liquid and vapor
phases.
 The square layouts are required where it is
necessary to get at the tube surface for
mechanical cleaning.
 The triangular arrangement allows more tubes
in a given space
TUBE BUNDLE
TUBE SIDE PASSES
14
4
 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 type.

 Front Head Type

A - Type B - Type C - Type

easy to repair cheapest type high pressure

and replace High press applications (>100 bar)
14
7
 Shell Type

E - Type F - Type

J - Type
K - Type
14
8
 Rear End Head Types

M - Type S - Type T - Type

Fixed Tubesheet Floating Head Pull-Through
Floating Head
unlimited thermal
expansion is possible
14
9
 U-Tube Heat Exchanger

 Fixed Tubesheet Heat Exchanger

 Floating Head Heat exchanger

15
2
 Many combinations of front header, shell and

rear header can be made. The most common

combinations for an E-Type Shell are given in the

following table but other combinations are also

used.
Fixed tubesheet U-tube Floating head
exchangers exchangers exchangers
AEL AEU AES
AEM CEU BES
AEN DEU
BEL
BEM
BEN
 In a fixed tubesheet exchanger,
This results in a and
construction and the tube bores can
be cleaned mechanically or chemically. However,

except to chemical cleaning.

 If
, it may be
necessary to incorporate an
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.
 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
, the tube bundle can be removed for
cleaning and small bundle to shell clearances can
be achieved.
 However, since

, it is normal

this type where the

 In this type of exchanger the
to the shell but
allowed to move or float.
 The use of a floating head means that
can be and the
 There are several rear header types that can be
used but the

 Suitable for the rigorous duties associated with

but is
than the equivalent fixed tubesheet
exchanger.
AES
16
1
AKT
16
2
The comparison of plate heat exchanger with the shell and tube
heat exchangers in terms of advantages and disadvantages are as
follows:

 The plate heat exchanger is best for liquid-liquid

duty with (flow rate)(specific heat) product
nearly the same for the two fluids. Flows with
dissimilar products can be applied with some
decrease in overall effectiveness.
 For high-pressure duty, a shell and tube
heat exchanger is preferred over a plate type
device. The basic construction of plate heat
exchangers makes them unable to contain
the high pressures.
 If application dictates special material like
stainless steel, plate type exchangers usually
has a lower cost than any tube type heat
exchanger. This is due to the large area per
unit volume of heat transfer surface
available in plate type compared to all
closed -type exchangers, and the ease of
manufacture .
 If an application does not need a heat exchanger
made of a special material, a shell and tube
device may be less expensive than a plate type.
This is because a plate type is normally not
constructed from mild steel. The shell and tube
heat exchanger is definitely preferred when the
device can be constructed from mild steel and a
close approach temperature is not required.
 One of the most expensive components of the
plate heat exchanger is the gasket, and the
material of construction of this component will
normally set the temperature limit of heat
exchanger operation. Typically this limit will not
be about 250°C.
 This obviously affects the value of F in the LMTD calculation.
 But, the major consideration may be the character of the fluid itself.

 A. Shell-Side
1. Viscous fluid to increase (generally) the value of "U"
2. Fluid having the lowest flow rate
3. Condensing or boiling fluid

 B. Tube-Side
1. Toxic fluids to minimize leakage
2. Corrosive fluids
3. Fouling fluids; increased velocity minimizes fouling but enhances erosion
4. High temperature fluids requiring alloy materials
5. High pressure fluids to minimize cost
 Temperature
 Pressure
 Pressure drop
 Viscosity
 Fouling and cleaning
 Corrosion
 High temperature stream preferable on tubeside
as fewer components on tubeside.

 High pressure stream favoured on tubeside: (a)

fewer components on tubeside , (b) tubes can
withstand much higher internal pressure.
 Presssure drop higher on tubeside for the
same HTC, especially for viscous liquids.
Thus viscous liquids are better handled on
the shellside.
 Gas pr. drop often lower on tubeside if a
single tube pass can be used, e.g., FTS
exch’s. However, if tube diameter has to be
increased, not worthwhile.
 Viscous liquids far  The greater the
better handled on viscosity, the
shellside: much greater the
higher HTC for difference
same pr. drop. between the
HTC’s.
  There is thus a direct
 Dirtier fluid contradictory demand
preferably routed between viscosity and
tubeside: shellside fouling.
more susceptible to  Final selection depends on
fouling, also more overall economics: which
difficult to clean. allocation produces the
 Unfortunately, the cheaper overall cost, initial +
dirtier stream is operating.
invariably more  Very common problem in
viscous. crude preheat trains
 If more corrosive  On the shellside, shell,
stream is on tubeside, shell cover, tubes,
channel and channel floating-head cover and
cover, floating-head shellside tubesheet face
cover and tubeside have to be of costlier
tubesheet face. metallurgy.
 Hence, better to route
more corrosive fluid
through tubeside.
APPLICATIONS FOR SHELL AND TUBE

Latent And / Or Sensible Sensible Heat Transfer

Heat Transfer

• Re boilers • Liquid to liquid

• Evaporators • Liquid to gas
• Condensers (No Phase Change)
 REBOILER AND EVAPORATORS
Kettle Type : -
4/25/2013
 REBOILER AND EVAPORATORS
Once Through Type : -
 REBOILER AND EVAPORATORS
Pump Through Type : -
 REBOILER AND EVAPORATORS

Thermosyphon Reboiler
 Indirect Contact Heat Exchangers
3- Air Cooled : -
 Advantages of Induce Draft Design
1. The hoods offer protection from
weather.
2. More efficient air distribution over the
bundle.

 Disadvantages of Induced Draft

Design
1. More difficult to remove bundles for
maintenance.
2. High temperature service limited due to
effect of hot air on the fans.
3. More difficult to work on fan assembly,
i.e. adjust blades due to heat from
bundle, and their location.
 Advantages of Forced Draft
Design
1. Easy to remove and replace
bundles.
2. Easier to mount motors or other
drivers with short shafts.
3. Lubrication, maintenance, etc.
more accessible.

 Disadvantages of the force

draft design
 The list of "advantages of the
induced draft design."
4/25/2013
 Large shell with packing at the bottom over
which water is sprayed
 Cooling by air flow and evaporation
 Air flow driven by forced or natural convection
 Need to continuously make up the cooling
water lost by evaporation
 Direct Contact Heat Exchangers
1- Cooling Tower: -
 Direct Contact Heat Exchangers
1- Cooling Tower: -
Advantages: -
•Effective in dry hot climate.
•Used in open areas.
• Easy Maintenance.
Disadvantages: -
• Noisy System.
• High cost of make up water.
Applications: -
• Refrigeration and air conditioning.
• Utility water cooling.