Heat Transfer Modes

Heat is transferred by three modes. i.e.,

1) Radiation Mode

2) Conduction Mode

3) Convection Mode

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1) Radiation Mode
Heat is radiated from heating source by
electromagnetic waves.
2) Conduction Mode
Heat is transferred by the vibration of metal
molecules in their vicinities
3) Convection Mode
Heat is transferred in liquid molecules due to
density difference caused by the application
of heat.

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 HEAT EXCHANGERS

USES
 To cool or heat a fluid (gas or liquid)
i.e., Cooler/Heater
 To condense a vaporized material .
(Condenser)
 To evaporate a liquid. ( Evaporator )
 To recover waste heat. ( Waste Heat
Boiler )

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 What are heat
exchangers for?
 To get fluid streams to the right
temperature for the next process
 reactions often require feeds at high temp.
 To condense vapours
 To evaporate liquids
 To recover heat to use elsewhere
 To reject low-grade heat
 To drive a power cycle
HEAT EXCHANGES (Unfired Equipment)

 Heat exchanger is the equipment used to

exchange heat between two fluids with
different temperatures, through a fixed wall,
without mixing them.

 Their names are based on the utilization.

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 Types of Heat Transfer
Equipment
1) Unfired Equipment:
Heat transfer occurs by conduction
and convection mode only. Examples of
this are coolers, condensers, and heat
exchangers.
2) Fired Equipment
Heat transfer takes place by Radiation,
conduction and convection modes.
Examples of this are steam boilers and
furnaces (heaters).
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 Main categories of
exchanger
Heat exchangers

Recuperator Regenerators
s
Wall
Wallseparating
separatingstreams
streams Direct contact

Most heat exchangers have two streams, hot and

cold, but some have more than two
 Recuperators/regenerato
rs
Recuperative
Has separate flow paths for each
fluid which flow simultaneously
through the exchanger
transferring heat between the Rotating wheel
streams
Regenerative
Has a single flow path which the
hot and cold fluids alternately
pass through.
 Shell-and-Tube Heat Exchangers
 Exchanger consists of a bundle of tubes enclosed
in a Shell
 Two fluids flow against the opposite sides of a tube
wall which separate them.
 One fluid inside the tubes and the other outside
the tubes.
 The fluids never come in a contact with each
other.
 Heat is passed from the hot fluid to the cold fluid.

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 Shell-and-Tube Heat Exchangers
 Tubes:
 Figure shows the
arrangement of Heat Tubes
Exchanger Tubes.
 It is desirable to place as
many tubes as possible
in a heat exchanger to
increase the surface area Tubesheet
for heat transfer.
 Tubes are attached to a
tube sheet as shown in the
figure.

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 Tube bundle
 The tubes and tube sheets
together are called the tube
bundle.
 The tube bundle is installed as a
single unit.
 The bundle is also removed as a
unit for inspection, cleaning and
repair.

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 Tube Pitch:
It is the shortest center-to-center distance between adjacent tubes.
Types
1) Triangular Pitch
 Tubes are laid out on triangular patterns
 More tubes can be fixed in the shell, so surface area will be
more.
 Prefer in low pressure system
2) Square Pitch
 Tubes are laid out on square patterns.
 Less tubes can be fixed in the shell, so surface area will be less.
 Prefer in high pressure area.
.

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 Tube Pitch:

(a) Square Pitch (b) Triangular Pitch

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Shell-side flow
Complete shell-and-tube
 Baffles
 It is a sort of plate which induce a turbulence
in the shell fluid and gives the support to
tubes.
Baffle Pitch
 Center-to-center distance between baffles.
 The baffle space is usually between one to
one-fifth the inside diameter of the shell.

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 Types of Baffle

ental Baffle

Segmental baffles

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 Types of Baffle

d – Doughnut Baffle

Disk-and-doughnut Baffles

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 Fixed Tube-Sheet H.
Exchanger
 In this heat exchanger , both ends of the
tube bundle are rigid and fixed.
 This allows for very little expansion of the
tubes.
 This heat exchanger is only used where the
temperature difference between the two
fluids is very small.
 For higher temperature differences it is
necessary to provide for differential
thermal expansion between the tubes and
the shell during operation
 This can be accomplished by the use of an
expansion joint on the shell, is shown in
figure on the next slide.
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 Fixed Tube-Sheet H.
Exchanger
Baffles
Partition

Fixed Tube-sheets

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 Fixed Tube-Sheet H.
Exchanger
With Expansion Joint

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 Floating Head Heat
Exchanger
 Exchanger having a tube bundle
which is removable from the shell.
 Consists stationary tube sheet, which
is clamped between the single
channel flange and a shell flange.
 At the opposite end of the bundle the
tubes are expanded into a freely
riding floating tube sheet or floating
head.
 A floating-head cover is bolted to the
tube sheet, and the entire bundle can
be withdrawn from the channel end.
 The shell is closed by a shell bonnet.
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 Floating Head Heat

Exchanger
The floating head eliminates the differential
expansion problem.
 The disadvantage are the simple geometry
which reduces the number of tubes hence
the heat transfer area.
 Also provides an undesirable flow channel
between the bundle and the shell.
 These limitations are removed by the
provision of “ split-ring ”

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 Floating Head Heat
Exchanger

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 Floating Head Heat
Exchanger
with Split Ring

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 Split-Ring
Tube Split
sheet ring

Floating
head
cover

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 U-Tube Heat Exchanger
 Consists of tubes which are bent in the form
of a U and rolled into the tube sheet.
 The tubes can expand freely.
 Baffles may be installed in the conventional
manner.
 The smallest diameter U-bend, can be
turned without deforming the outside
diameter of the tube at the bend has a
diameter of three to four times the outside
diameter of the tubing.
 This omit some tubes at the center of the
bundle, depending upon the layout.

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 U-Tube Heat Exchanger
 The tube bundle can be removed from the heat-
exchanger shell.
 Each tube is free to expand or contract without
any limitations being placed upon it by the other
tubes.

 The number of tube holes in a given shell is less

than that for a fixed-tube-sheet exchanger
because of limitations on bending tubes of a very
short radius.

 The U-tube design reduces the number of joints.

In high-pressure construction this feature is
important in reducing both initial and
maintenance costs.
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 U-Tube Heat Exchanger

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 Kettle Type Reboiler
 Exchangers may be installed either vertically or
horizontally in the field .
 This design is frequently found as heating units at the
base of distillation columns.
 In this type, liquid is vaporized in the Shell using
steam or other hot material passing through the
tubes.
 An overflow baffle makes sure the tubes are always
submerged in the liquid.
 The vapors, can be returned to the distillation
column.
 Non evaporated liquid returns as bottom product.

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 Kettle Type Reboiler
Vapour
back to the
column

Steam

Condensate Liquid from Bottom

the bottom of Product
the column

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 Tank Heaters
 The tank heater are usually
U-tube bundle.
 This design is often used
for storage tanks of heavy
fuel oils and high viscosity
oils
 High temperature reduce
the viscosity of oil and
makes its pumping easy.
 Here heating media is
steam which pass through
the tubes.

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 Exchanger Operation and
.
Maintenance
 The start up / shutdown must be done properly to avoid
equipment damage and possible injury to personnel.
 The unit must be warmed up and cooled off slowly.
 A sudden change in temperature causes excessive expansion
or contraction of the metal. This can damage the tubes and
leaks can be develop.
 Tubes may loose in the tube sheet. Vibration can cause the
loosening of tubes in the tube sheet.
 A large pressure difference between inside and outside of
the tubes may also collapse the tubes.
 Both sides should be vented on start up to remove any
trapped air.
 The cooled fluid should be introduced first when starting up
a heat exchanger.

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 Exchanger Operation and
Maintenance
 When shutting down, the hotter fluid should be shut off
first.
 Tubes must be cleaned periodically.
 Pressure tests and leak test can be used to check the tubes
in a bundle.
 A pressure test consists of filling the exchanger with liquid
or air to pressure higher than atmosphere pressure.
 A loss of pressure after a period of time will indicate a leak
 Leaky tubes may be re-rolled if they are leaking at the tube
sheet.
 If only a few tubes are leaking somewhere in the middle of
the tube, they may be plugged.
 This may be repeated until the number of tubes plugged
interferes with efficient exchanger operation.

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 Exchangers Using Water
 Water is corrosive to steel,
 Particularly when the tube-wall temperature is high
and dissolved air is present,
 Therefore, water is kept on tube side to avoid the
corrosion on both shell and tube .
 Also, when water travels slowly through a tube, dirt and slime
resulting from microorganic action adhere to the tubes
 Which would be carried away if there were greater turbulence.
 As a standard practice, the use of cooling water at velocities less than 1
m/s should be avoided.
 Still another factor of considerable importance is the deposition of
mineral scale.
 When water of average mineral and air content is brought to a
temperature in excess of 50 oC,
 It is found that tube action becomes excessive, and for this reason an
outlet water temperature above 50 oC should be avoided.

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 Exchangers Using
Steams
 Steam is used as heating medium.
Steam is used as heating medium.
 Hot steam condensate is corrosive, and care must
be exercised to prevent condensate from
accumulating within an exchanger where
continuous contact with metal will cause damage.
 So, effective steam trap is must.
 It is advantageous in heating to connect the
steam to the tubes of the heater rather than the
shell.
 In this way, since the condensate may be
corrosive, the action can be confined to the tube
side alone.
 Where as if the steam is introduced into the shell,
both may be corroded.

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 Air-Cooled Heat
Exchangers
 In the air-cooled exchanger, ambient air is forced or
induced by a fan to flow across a bank of externally
finned tubes.
 A typical air cooler has :
i) A horizontal section containing finned tubes,
ii) A steel supporting structure with plenum
chambers and fan ring axial-flow fan,
iii) Drive assembly, and miscellaneous accessories
such as louvers, fan guards, fencing and hail
screens.

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 Air-Cooled Heat
Exchanger

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 Tube Bundle
 The tube bundle consists of headers,
finned tubes, structural-steel side
channels, and supports.
 Tube bundle are generally designed to
be rigid and self-contained and they
expand independently of the supporting
structure.
 The fines on the tubes, increase the
heat transfer area
 Aluminum is the most economical fin
material. Steel finned tubes operate
well at higher temperatures.
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 Finned Tube

F in s

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 Plate and frame
 Plates hung vertically and
clamped in a press or frame.
 Gaskets direct the streams
between alternate plates and
prevent external leakage
 Plates made of stainless steel or
higher quality material
 Plates corrugated to give points
of support and increase heat
transfer
 Plate types

Corrugations on plate
improve heart transfer
give rigidity

Many points of
contact and a
tortuous flow path

Chevron Washboard
 General
view of
plate
exchanger
“Plate
exchanger”
normally refers
to a gasketted
plate- and-
frame
exchanger
Flow Arrangement within a
Gaskets
PHE
arranged for
each stream to
flow between
alternate plates

Alternate plates (often same plate types inverted)

 Cooling Towers
 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

or cooling of fluids
Agitated Vessel
Used for batch heating

 An agitator and baffles

promote mixing
 A range of agitators are
used
 Often used for batch
chemical reaction
 Printed circuit heat
exchanger
 Plates are etched to
give flow channels
 Stacked to form
exchanger block
 Block diffusion
welded under high
pressure and
temperature
 Bond formed is as
strong as the metal
itself
Printed circuit exchanger

Note that “compact” does not

mean small but means large
surface area per unit volume
 Fans
 Axial-flow fans are large-volume, low-
pressure devices.
 Fan diameters are selected to give
velocity pressure of approximately 0.1
in. of water.
 Total fan efficiency is about 65 per cent,
and fan drives usually have a minimum
of 95 per cent mechanical efficiency.
 Usually fans are provided with four or six
blades.
 Fan diameter is generally equal to or
slightly less than the bundle width.

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 Fans
 At the fan tip speeds required for economical performance, a
large amount of noise is produced. The acceptable noise level
at the location of the air cooler should be considered in setting
the maximum speed.
 The axial-flow fan is inherently a device for moving a
consistent volume of air, when blade setting and speed of
rotation are constant.
 Variation in the amount of air flow can be obtained by
adjusting the blade angle of the fan and the speed of rotation.
 The blade angle can be either (1) permanently fixed, (2) hand
adjustable, or (3) automatically adjusted. Air delivery and
horsepower are a direct function of blade pitch angle.
 Electric motors are the most common fan drivers.

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 Air-Cooled Heat
Exchangers
Advantages
Advantages
 Air piping system is not required.
 There is no limit to the air supply volume.
 There is practically no fouling on the outside
surfaces of the tubes.
 It is economical and easily maintained.
Disadvantages
 Minimum cooling level is limited by ambient
temperature.
 During warm periods, it is common to water
spray on the fin tubes which increases the
Fin Fan capacity for heat removal due to the
cooling effect of the evaporating water.
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 Forced Draft Air-Cooler
 The forced-draft unit pushes air across the
finned tube surface.
 The fan is located below the tube nest.
 The forced-draft unit requires less horsepower
because it moves air at the lowest available
temperature (or highest density).
 Structural costs are less
 Mechanical life is longer.
 The forced-draft design offers better
accessibility to the fan for :on-stream
maintenance and fan-blade adjustment.
 The design also provides a fan and V-belt
assembly, which are not exposed to the hot-air
stream that exists from the unit.

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 Induced Draft Air Cooler
 It has the fan above the tube bundle
 The air is pulled across the finned tube
surface.
 The induced-draft unit gives better
distribution and less recirculation for
comparable plenum heights.
 Induced-draft design provides more
even distribution of air across the
bundle, since air velocity approaching
the bundle is relatively low.
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 Induced Draft Air Cooler
 Induced-draft units are less likely to recirculate the
hot exhaust air, since the exit air velocity is several
times that of the forced-draft unit.
 Induced-draft design more readily permits the
installation of the air-cooled equipment above other
mechanical equipment such as pipe racks or shell-
and-tube exchangers.
 In a service where sudden temperature change
would cause upset and loss of product, the induced-
draft unit gives more protection in that only a
fraction of the surface (as compared with the forced-
draft unit) is exposed to rainfall or snow.

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 Forced and Induced Draft Air
Coolers

motor motor

Induced Draft Forced Draft

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