Heat exchanger

AGENDA
Introduction

Types of heat transfer

Heat transfer applications

Heat exchangers types

Problems affecting heat exchanger performance

 Applications of heat exchangers

Condensers
evaporators
air preheaters
oil coolers.
 HEAT & TEMPERATURE

HEAT is the amount of energy which obtained by the difference of

TEMPERTURE between two substance , chemical reaction or
friction

TEMPERATURE is the indication for amount of heat which lost

or obtained through substance molecules

Specific Heat
It is generally defined as the amount of heat needed to change the
temperature of a pound of a particular substance 1F
THE HEAT ENERGY can
transfer by three
modes between two
substances till thermal
equilibrium
 Method of heat transfer ()

Radiation ()
Convection ( )
Conduction ()
1- Radiation ()

heat is transferred by
electromagnetic wave radiation, like
transferring the heat from sun to
earth and this type not famous at
heat exchangers but famous at
heaters
2- Convection ( )

Convection heat transfer

involves fluids, either liquids or
gases, The movement of the
fluid transports the heated fluid,
as well as its thermal energy, to
another location.
 3- Conduction ( )

Conduction is the heat transfer between two

substances by direct transference of
molecular kinetic energy. Conduction occurs
when a hot substance comes into contact
with a cold substance
Factors Affecting Heat Transfer between Fluids:-

Type of Fluid or Substance (specific heat)

Thickness of Material

Type of Materials
Thermal conductivity

Surface Area

Specific Gravity of Fluids

Turbulence of Fluids laminar fluids

Temperature Difference

Velocity of the fluids in the tube

Direction of flow

Amount of Fluid

Fouling or Scale Buildup

2 - According to construction
A- Double tube heat exchangers (hairpin )
Fluid passes through the inside of the inner pipe and the
second fluid flows through the annulus between the
outside of the inner pipe and the inside of the outer pipe

Used for services with small heat duties.

Cleaning and maintenance more difficult

B- Plate type heat exchangers
The plate heat exchanger is widely recognized today as the most economical and
efficient type of heat exchanger on the market.

Less Fouling

Easy to Remove and Clean

Expandable

High Efficiency

Compact Size

The plate heat exchanger is designed with either single-pass or multi-pass flow,
depending on the duty.

Not use in high pressure condition

C- Spiral heat exchanger
D - Shell and tube heat exchanger:-
 The component of shell and tube heat
exchangers

Tubes

Shell

Baffles

Vent

Drain

Shell inlet nozzle

Shell outlet nozzle

Tube inlet nozzle

Tube outlet nozzle

1. TUBES ()
lower temperature fluid
lower viscosity
higher corrosion fluid
 SHELL
higher temperature fluid
Higher viscosity
lower corrosion fluid
 BAFFLES
The baffle is important part at heat exchanger
Increase heat transfer efficiency
Prevent tubes erosion
Shell-and-tube exchangers are
named by the Tubular
Exchanger Manufacturers
Association TEMA (1988)
 Objective of codes & Standards
(Shell &Tube Heat Exchanger )

dimensional value
Suitable precaution
TYPES OF REAR END
TYPES OF FRONT END
TYPES OF SHELL
TEMA Designation System Example
 TEMA CLASSIFICATION
In TEMA There are three Classes according to the
severity and the type of process the exchanger is
Used

TEMA Class (R) ======== Refinery

TEMA Class (C) ======== General

TEMA Class (B) ======== Chemical

TEMA Requirements for Class R, C, and B Exchangers
 Selection of TEMA Heat Exchangers
for Different Applications
Front head

Main factor for selecting front head

Accessibility to tube sheet for

Cleaning

Inspection

Replacement of tubes

Types of cleaning for shell side

Design condition P & T

cost
 Selection of TEMA Heat Exchangers
for Different Applications
Shell type

TEMA shell type is the E shell it is most suitable for most

industrial process cooling applications and easy to fabricate.

TEMA-F shell provides higher heat transfer and close approach

temperature.

TEMA G, H and j shell designs are most suitable for phase

change applications and provide low pressure drop.
The TEMA K shell,
Also termed a kettle reboiler

It is specified when the shell side stream will undergo vaporization.

The liquid level of a K- shell design should just cover the tube
bundle, which fills the smaller diameter end of the shell.

The empathy space over the bundle help in separation of liquid

from outgoing vapor.

Tube layout patterns
 Tube pitch
It is the geometry and the distance between the holes
drilled in the tube support baffles
Pitch type
1-triangular pitch
in line type
staggered type
2-Square pitch
in line type
staggered type (small pitch-large pitch)
Tube pitch: it is the distance between the center of
two adjacent tubes.
minimum tube pitch of 1.25 times the tube O.D .
Triangular pitch type

Advantages :
many tubes are squeezed into small shell
the spacing promote turbulence and good heat transfer
Disadvantages :
can not clean by hydroblasting.
should never used in fouling service

Square pitch type (in line)

Advantages :
Easy to clean.
hydroblasting is possible
Disadvantages :
reduce no. of tube in the same shell ID.
created less turbulences ,
reduce heat transfer efficiency.
Square pitch type (staggered)

Advantages :
Tubes promote turbulence (improve heat transfer)
Easy to clean.
relatively easy to hydroblasting
Disadvantages :
reduce no. of tube in the same shell ID.
reduce heat transfer efficiency.
Factors to considered of tube pitch

The heat transfer coefficient.

Pressure drop.
Number of tubes to a given diameter of shell.
Access to the outer surface for cleaning.
 Number of Tubes
The number of tubes depends upon the fluid
flow rate and the available pressure drop.
The number of tubes is selected such that
Tube-side velocity for liquids range from
3 to 8 ft/s (0.9-2.4 m/s)
Shell-side velocity from 0.6-1.5 m/s ( 2
to 5 ft/s)
1 -fixed-tube-sheet
One Pass
Two Pass
 Disadvantage

Relatively hard to remove or replace

Used for low temperature differences.

2 -floating-head heat exchanger
 Advantage & disadvantage

Manufacture is more expensive than for the

fixed-tube sheet.

the channel head make maintenance more

easy for bundle tube .

allows large temperature difference without

excessive thermal stress on the equipment .
3. U-tube HEAT EXCHANGER
 Advantage &disadvantage

Like the floating-head, the U-tube is a

removable bundle and has similar advantages .

Cleaning inside the tubes is extremely

difficult.

Used in high pressure conditions.

Reboilers
Device like heat exchanger used for heating
the bottom of towers.

Reboilers uses heating media like steam or

hot oil.

The main types of reboilers are

Kettle reboilers
Thermo siphon reboilers
1. Kettle reboilers
1. Thermosyphone Reboilers
(horizontal) and ( vertical )
 Heating
Heating Medium
Medium

Bottoms Product

Bottoms Product

Kettle Horizontal Thermosiphon

Procedure to Take a Heat Exchanger out of Service :-

The hot fluid must be shut off before the cold fluid.

After the hot fluid has been shut off, the cold fluid can be shut
off on both inlet and outlet valves.

Both shell and tube side should now be pumped out to slop or
drained down.

Both inlet and outlet lines should be blanked off for safety.

the exchanger should be steamed out before opening to the

atmosphere .
Procedure to Place Heat exchanger in Service:-

Cheek the exchanger carefully to ensure that all plugs have been replaced
and that all pipe work is ready for the exchanger to be placed in service .

All valves should be in the shut position.

Purging and testing

Line up the system.

Open hot and cold fluid vent valves

Open cold fluid inlet valve &vent all air when liquid full, then Close cold
fluid vent valve.
7. open hot fluid outlet valve and vent all the air, then close hot fluid
vent valve.

8. At this stage, the exchanger is liquid full of both hot and cold
flowing fluids - open cold fluid inlet and hot fluid outlet valves fully.

9. The cold fluid valve outlet may be opened slowly until the cold
fluid is passing through the exchanger.

10. Start opening the hot fluid inlet valve slowly.

11. Both valves, the cold fluid outlet valve and the hot fluid inlet
should be open slowly until fully open.
 Air-Cooled Exchangers

An air-cooled exchanger is used to cool fluids with ambient air.

The basic components are:-

1. One or more tube sections.

2. One or more axial flow fans.
3. Fan drivers.
4. Speed reducers.
5. An enclosing and supporting structure.

Air-cooled exchangers are classed as :-

1. Forced draft when the tube section is located on the discharge side of the
fan.
2. Induced draft when the tube section is located on the suction side of the
fan.
 Disadvantages of induced draft are:

1. Effluent air temperature should be limited to 200F, to

prevent potential damage to fan blades, bearings, V-belts, or
other mechanical components in the hot air stream.

2. The fan drive components are less accessible for

maintenance, which may have to be done in the hot air
generated by natural convection.

3. For inlet process fluids above 350F, forced draft design

should be used; otherwise, fan failure could occur (the fan
blades and bearings subject to excessive temperatures).
 Advantages of forced draft are

1. Slightly lower horsepower since the fan is in cold air.

(Horsepower varies directly as the absolute
temperature.)

2. Better accessibility of mechanical components for

maintenance.

3. Easily adaptable for warm air recirculation for cold

climates (to prevent from freezing)
HEAT EXCHANGERS PROBLEMS

Heat Exchanger Fouling .

What is Fouling ?
Fouling is generally defined as the
accumulation of unwanted materials on the
surfaces of processing equipment. It has been
recognized as a nearly universal problem in
design and operation and affects the operation
of equipment in two ways:
The fouling layer has a low thermal
conductivity. This increases the resistance to
heat transfer and reduces the effectiveness
of heat exchangers increasing temperature

As deposition occurs, the cross-sectional

area is reduced, which causes an increase in
pressure drop across the apparatus
 Types of Fouling

1- Scaling involve the crystallization of solubility salts

2- Particulate Fouling involves the deposition of particles suspended in the

fluid

3- Chemical Reaction Fouling (Polymerization, cracking and coking of

hydrocarbon liquids at high temperature are prime examples).

4- Corrosion Fouling(chemical reaction between the heat transfer surface and the
fluid stream producing corrosion products which, in turn, foul the surface).

5- Biofouling involves the accumulation of biological organisms at

the heat transfer surface.
 Cleaning of Heat Exchangers:-

Five possible cleaning techniques are recognized

for condenser tubes, based on field testing.

Hydro blast

Acid Cleaning

Brushes and
Rubber Plugs

Tube Scrapers

Chemical Additive